2012 FV ICMEM Cover PDF

MANUFACTURING ENGINEERING AND MANAGEMENT
Proceedings of 2nd International Conference on

MANUFACTURING ENGINEERING & MANAGEMENT 2012
Organised by:
Faculty of Manufacturing Technologies with a seat in Preov,
Technical University of Koice, 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
Preov
Slovak Republic
ManufacturingEngineeringand
Management
SergejHloch
JozefHusr
LuciaKnapkov
IvanLazr
Editors
Preov,57December2012

This book contains the papers suggested by the reviewers for publishing and presentation at the Second
InternationalMANUFACTURINGENGINEERING&MANAGEMENT2012tobeheldduring5th7thDecember
2012inPreov,SlovakRepublic,EuropeanUnion.
Note
Thispublicationwasreproducedfromthemanuscriptssuppliedbyauthorsandcoauthors.Thelayout,the
figuresandtablesofsomepapersdidnotconformexactlytothestandardrequirements.Insomecaseswas
thelayoutofthemanuscriptsrebuild.Theeditorsarenotresponsibleeitherforthestatementsmadeorfor
theopinionexpressedinthatpapers,publishedintheproceedingsofMANUFACTURINGENGINEERING&
MANAGEMENT2012.
Editors: HLOCHSergej
HUSRJozef
KNAPKOVLucia
LAZRIvan
LayoutandDesign: HLOCHSergej
CoverDesign: HUSRJozef
Publisher:
FacultyofManufacturingTechnologiesTechnicalUniversityofKoicewithaseat
inPreov
AllRightsReserved
2012FVTTUinKoicewithaseatinPreov
Nopartofthisworkmaybereproduced,storedinaretrievalsystem,ortransmittedinanyformorbyany
means, electronic, mechanical, photocopying, microfilming, recording or otherwise, without written
permissionfromthePublisher,withtheexceptionofanymaterialsuppliedspecificallyforthepurposeof
beingenteredandexecutedonacomputersystem,forexclusiveusebythepurchaserofthework.
ISBN9788055312163
II
BriefContents
Forewords...........................................................................................................V
ChairmanForeword............................................................................................V
ForewordoftheMayoroftheCityofPreov.....................................................VII
Generalinformation............................................................................................VIII
ProgrammeCommittee......................................................................................IX
Proceedingscontents..........................................................................................X
KeynoteLectures................................................................................................1
Papers.................................................................................................................44
KeynoteLecture..................................................................................................210
Advertising..........................................................................................................217
III
Mydesire,sir,istoescapefromtradewhichIfind
viciousandselfishandtobecomeaservantofscience
whichIimaginemakesitspursuersamiableand
liberal.
MichaelFaraday
IV
ChairmanForeword
Dear
Participants,
Colleagues,Dearfriends,
included among the strongest forces helping get the ideas

dressed into reality which change the way of life, habits and
viewovertheworldofeverysocietyinclusiveofoursaswell.
Specifically, technologies represent processes which through
theexplicitorimplicitresearchanddevelopmentstage,i.e.by
application of scientific knowledge not only do allow
commercialproductionofgoodsandservices.
Dear
my great friend Prof. Draan

Kozak, wrote me in one email
Democracyliesontheconscious
individuals who are living for
innovations in science, especially
in gaining new experience based
on experiments. Thank you my
But as Albert Einstein said: It is not enough that you should

understandaboutappliedscienceinorderthatyourworkmay
increasemansblessings.Concernforthemanhimselfandhis
fate must always form the chief interest of all technical
endeavours...Yes,withouttheunsolvedissuesandissuesnot
beingsolvedonewouldpossessnothing.Followingpagesdeal
with the issues of our ancestors and consequently with the
ones is having occurred in the course of experimental work,
yourwork.
Friendforyourbigwords.
Whenexaminingtheworldaroundeitherathomeorwork,
when travelling and entertaining oneself or working results
of the work of anonymous scientists and engineers are being
used. Science, technology andmanagement surprisingly bring
new inventions, breakthroughs, applications and permeate in
other spheres of human life. 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. Many times the reason rests in waving
theadvancesorinventionsasideorinbecomingfrightenedof
them. In fact, science, research and related reshaping of
natural or artificial substancematerial through technologies
significantlyaffectsocietydevelopment.
ThisbookincludestheproceedingoftheSecondInternational
Scientific Conference on Manufacturing Engineering and
Management 2012 organized by Manufacturing Management
DepartmentFacultyofManufacturingTechnologies,Technical
University of Koice with a seat in Preov, where the latest
findings in science and engineering concerned with the
2012
technology systems operation are reported. ICMEM
conference is arranged under the patronage Dean of the
Faculty of the Manufacturing Technologies Technical
UniversityofKoicewithaseatinPreovProf.Ing.JozefNovk
Marcinin, PhD., and Vicerector of University of Prof., Dr.,
Sc.IvanSamardiandMayorofthePreovTownJUDr.Pavel
Hagyari.
Technologies and engineering are overcoming distances yet

absence of certain closeness to the man and chiefly among
people is apparent. The content of the words in this
proceeding is not focused solely on knowledge having been
acquiredthrougharduousandchallengingresearchbutitisa
desiredmetamorphosisofideashavingoccurredinyourmind
earlier to become familiar with other so far unknown
miracles.Towhatextentisrealityaccessible?Thequestion
should be raised other way. Why? Because reality includes
both objects and events occurring beyond the human
cognition, perception, imagination, fantasy. Pursuant to the
articlepublishedinScientificAmericaneachpersondisposesof
different limited field of vision exceeding the borders of
imaginationandfantasyoftheworld.However,certainspace
exists between the borders of cognition and fantasy. It is the
spaceforideaswithintheframeofwhichthemostsignificant
moments, milestones of human life commence. In point of
causality it is the area of undefined reasons and interactions
many times vaguely described by terms of fate or accident.
Those are exactly the words used to express degree of
unawarenessofcausalchainofreasonsandconsequencesthat
correlateswiththecorrectnessofevaluationoftheparticular
actionhavingoccurredintimeandspace.
This year, ICMEM Organizing Committee received more than

64submissionswhichauthorsandcoauthorsandparticipants
are from 20 different countries of the world. Reviewers and
Members of the Program committee and their
recommendationsusedforaselectionofcarefullyreviewedall
submissions.Accordingtheiradviceswereaccepted47papers.
In addition to the contributed papers, prominent researches
wereinvitedtogivekeynotelecturesintheirrespectivefields
of competence. For running a conference of this magnitude,
financialsupportisessential.Wearethankfulforthegenerous
donation by WELDEX, Ltd., Preov, Slovak Republic, A.G.E.S.
Ltd.,Olcnava,SlovakRepublic,SPINEASolutionforPrecision,
Preov,SlovakRepublic,1stPresovtoolmakingcompany,Ltd.,
Preov,SlovakRepublic,VIAMAGNA,Preov,SlovakRepublic,
DRC, Ltd., Preov, Slovak Republic, AVON, Ltd., Bratislava,
SlovakRepublic.
Thisconferencebearsallthehallmarksofsuccess.Thisisdue
to the great team work. I would like to thank all those who
2012
helpedinorganizationoftheICMEM conferenceespecially
our colleagues from Department of Manufacturing
Management.Smoothrunningoftheconferencecanbehardly
imagined without the devoted presence of Ing. Lucia
Knapkov,PhD.,Ing.Husr,PhD.,Ing.PavolHreha,PhD.,Ing.
Human mind, fortunately, is not partial to mess. For the

presenttheonlyworkingmeans,kindofbattery(orlight)in
the space of unknown matters is exploration magnifying
notionalradiusofcognition.Interalia,sciencemeansstudying
and knowing (learning). Technologies mean knowing how to
do. Management means how to organize. Jointly they are

Vincent Perel and Jozef Chomani the owner of Via Magna.
Thanks belong to the reviewers for their diligence and expert
reviewing.Lastbutnotleastaretheauthorswhodeservebig
thank you, their research and development efforts are
recorded in those proceedings. We wish you warm welcome
2012
and hope that your participation in ICMEM will be
enjoyableandalsoprofessionallyrewardingandwearehoping
that the proceedings will be helpful to all scientists and
engineers.
At last I would like to say big THANK YOU, to my friend prof.

PeterFeko,wholeftusforever,thisyear.Weneverforget.
HlochSergej,Assoc.,Prof.,Ing.,PhD.
VI
ForewordoftheMayoroftheCityofPreov
fortheuniversitytogetfeedbackontheireducationprograms
directlyfromthepractice.Tobecomeaprofessional,onehas
tobeeducatedandhaveagoodexperienceinthefieldofhis
studyprogram.TheconnectionofthecityandtheUniversity
will secure not only opportunity for graduates, but also
opportunity for students to practice during their studies and
seehowthetechnologiesareusedinindustry.
DearLadiesand
Gentlemen,
I am delighted to attend
today
the
second
International
Scientific
Conference
on
Manufacturing Engineering
and Management 2012. I
believe
that
this
conference
will
be
beneficial not only for the
participants but also for
the
development
of
cooperationbetweenUniversityandtheCityofPresov.
One of the ideas of the cooperation between the city of

Preov and the Faculty of Manufacturing Technologies is to
makesuitableenvironmentforstudentsinourcity.Oneofthe
major aims of the city on this successful way is to help
students to resolve the problem with an accommodation by
buildingupofnewflats.TheMunicipalityhasfurtherambition
to build up wellness centres for students and for inhabitants
of Preov. We expect that the University graduates will fulfil
the requirements and expectations of the growing city and
new coming investors. Education will remain one of the
priorities of the citys development. The cooperation of the
City and the Faculty is a significant step forwards by reason
thattheylivedindependentlyuntilthistime.Theirconnection
is an important element for the experience of the graduates
andforstudents.
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
modernandprosperingecologicalcitythatusestheadvanced
technologies.
Presovhasthegreatpotentialoftheutilizablenaturalenergy.
Our main objective is especially the utilization of geothermal
energy for heating and also using of the energy for
developmentoftourismandforproductionofelectricity.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. We would like to utilize the other
alternative energy sources like solar energy and biomass.
Cleanandhealthyenvironmentbelongstothemainpriorities
whenwearetalkingabouttheCityofPreov.
At the present time, the City of Preov makes an effort to

belongtothesefastgrowingcitiesthatwillbeabletorespond
to solving such a big challenge as the climate changes and
globalwarmingare.ThecitizensofPreovdounderstandthe
needtocutdownenergyusageandtheimportanceofcombat
against climate changes. Municipality of Preov has clear
prioritiestoachieveconcreteresultsforwhichtheconnection
betweentheFacultyandtheCitywillbebeneficial.
AfterdiscussioninEnergyCitesPreovhasbeenselectedasa
pilot city for the IMAGINE Campaign. EnergieCits is the
associationofEuropeanlocalauthoritiesforthepromotionof
local sustainable energy policies. Ladies and Gentlemen,
PreovisaseatoftheUniversityofPreov.Thestudentsfrom
all parts of Slovakia are studying at the University. There are
alsootherfacultiesinthecityandoneofthemistheFaculty
ofManufacturingTechnologies,TechnicalUniversityofKosice.
Thecityhasanambitiontoestablishanenvironmentthatcan
offer opportunities for highclass education and also for
studentsemployment.Thatisthereasonwhytheremustbe
connection between the city, educational institutions and
industrial parks. The city needs educated and ambitious
people in order to become a prominent European centre. It
needspeoplewhowillnotleavethecitybutpeoplewhowill
stayinthecitythatcancareofthem.
TheCityofPreovhasanambitiousaimtobealeaderinthe
EasternSlovakiaregion.Preovisonthebestwaytobecome
modernanddynamiccitythatisinterestingforitsinhabitants
as well as it is attractive for tourists. There are also OPAL
MINESinourregionthatareveryattractivetouristicattraction
with its unique "nobel opal". Our plan is to connect OPAL
MINES, SALT MINES and GOLDEN MINES together under the
openair mine's museum and to create a great place to visit.
We are pleased by the attention of foreign visitors, officials
andrepresentativesoftheauthoritiesoftheEuropeanUnion
thatweregularlywelcomeatourCityHall.
The message of this Conference would be to bring together
Faculty and the City and thus enable Preov to become the
ecological and technological city. We look forward to our
cooperation with Technical University in Kosice through its
FacultyofManufacturingTechnologieswithseatinPreov.
Ihopethatourcollaborationwillhelpustoestablishastrong
base for the graduates and their potential employers. The
relationshipwithindustrialparkswillimprovethelevelofthe
higheducationnotonlyatthisparticularFacultybutalsoitis
goodopportunityfortheothereducationalinstitutionsinour
city. It is also one of the solutions for students to gain
experienceinthefieldoftheirstudiesanditistheopportunity
IwishwewillmeetagainonthefurtherConferencein2014.
JUDr.PavelHagyari
MayoroftheCityofPresov
VII
ICMEM2012
2NDInternationalScientificConferenceMANUFACTURINGENGINEERING&MANAGEMENT
Inaugurated in 2010, 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, and to promote the importance of intellectually
challenging,relevantindustrialtrainingasanintegralpartofhighereducation.
Organisedby:
DepartmentofManufacturingManagement,FacultyofManufacturingTechnologieswitha
seatinPreov,TechnicalUniversityofKoice,Slovakia,
Mechanical Engineering Faculty in Slavonski Brod, J.J. Strossmayer University of Osijek,
Croatia,
Industrial Engineering Department, Faculty of Engineering, Marmara University Istanbul,
Turkey.
Incooperation
SlavonskiBrodTown(Croatia)
InstituteofGeonicsASCR
DistrictAuthorityofPreov
PreovTown
Financiallysupportedby(inalphabeticalorder):
1stPresovtoolmakingcompany,Ltd.,Preov,SlovakRepublic
(http://www.1pn.sk)
A.G.E.S.Ltd.,Olcnava,SlovakRepublic
(http.//www.agesmetal.sk)
AVON,Ltd.,Bratislava,SlovakRepublic
(http://www.avon.sk)
DRC,Ltd.,Preov,SlovakRepublic
(http://www.drc.sk)
(http://www.spinea.sk)
(http://www.topvar.sk/)
(http://www.weldex.sk/)
SPINEASolutionforPrecision,Preov,SlovakRepublic
TOPVARBreweryariBrewery,Vekari,SlovakRepublic
VIAMAGNA,Preov,SlovakRepublic
WELDEX,Ltd.,Preov,SlovakRepublic
VIII
ScientificCommittee|inalphabeticalorder
ALHELALATOMAR
ALMOMANIMUFADI
ALNIMRMA.
BADEALEONARDO
DIMACONSTANTINIOAN
DURAKBASANUMANM.
FEKOPETER
FOLDYNAJOZEF
GRABARAJANUSZ
GUBELJAKNENAD
HODOLIJANKO
CHATTOPADHYAYASOMNATH
ILLSBLA
JACKSONMATS
JAVADIYASHAR
KHADRAWIAF
KRIVOKAPIZDRAVKO
LACATUSELENA
LEEHOSUNG
LEGUTKOSTANISLAW
MAHALIK,N.,P.
MARIANAMAN
MIKACTONI
MLDKOVLUDMILA
MODRKVLADIMR
OHLDALMILOSLAV
PETROPOULOSGEORGE
PITORAJAROMR
RAJAKARUNAKARANS.
RAJCZYKJAROSLAW
RAOSPERO
RIBEIROJOS
ROKOSZKRZYSZTOF
RUGGIEROALESSANDRO
SAMARDIIVAN
SARHANAHMAD
SEDMAKALEKSANDAR
SENNAROLUBAHAR
SHARIATIAZADED
SHARMAVINAY
STEGAROIUION
STOIANTUN
SUDHAKARAPANDIAN.R
SURZENKOVANDREI
IMUNOVIGORAN
TOZANHAKAN
VAYVAYZALP
VENKUMARP.
YURCIMEHMENTEMIN
ZAMANABEDULLAH
NEWYORKINSTITUTEOFTECHNOLOGY
APPLIEDUNIVERSITYOFJORDAN
UNIVERSITYOFSCIENCEANDTECHNOLOGY
VALAHIAUNIVERSITYOFTARGOVISTE
VIENNAUNIVERSITYOFTECHNOLOGY
VBTUOSTRAVA
INSTITUTEOFGEONICSASCR
CZESTOCHOWAUNIVERSITYOFTECHNOLOGY
UNIVERSITYOFMARIBOR
UNIVERSITYOFNOVISAD
INDIANSCHOOLOFMINES,DHANBAD
UNIVERSITYOFMISKOLC
MLARDALENUNIVERSITY
ISLAMICAZADUNIVERSITY,SEMNANBRANCH
ALHUSONCOLLEGEUNIVERSITY
UNIVERSITYOFMONTENEGRO
POLITECHNICAUNIVERSITYBUCHAREST
KOREAAEROSPACERESEARCHINSTITUTE,DAEJUN
UTPOZNA
CALIFORNIASTATEUNIVERSITY
UNIVERSITYOFPETROSANI
UNIVERSITYOFRIJEKA
UNIVERSITYOFECONOMICS,PRAGUE
TECHNICALUNIVERZITYOFKOICE
SFVTBRNO
UNIVERSITYOFTHESSALY
VBTUOSTRAVA
KALASALINGAMUNIVERSITY
CZESTOCHOWAUNIVERSITYOFTECHNOLOGY
J.J.STROSSMAYERUNIVERSITYOFOSIJEK
UNIVERSITYOFSAOPAULO,BRAZIL
KOSZALINUNIVERSITYOFTECHNOLOGY
UNIVERSITYOFSALERNO
NEWYORKINSTITUTEOFTECHNOLOGY
UNIVERSITYOFBELGRADE
MARMARAUNIVERSITY,ISTANBUL
SHARIFUNIVERSITYOFTECHNOLOGY
BIRLAINSTITUTEOFTECHNOLOGY,MESRA
TALLINNUNIVERSITYOFTECHNOLOGY
TURKISHNAVALACADEMY,ISTANBUL
MARMARAUNIVERSITY,ISTANBUL
TUISTANBUL
DEPT.OFINNOVATION,DESIGNANDDEV.
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
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IND
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CRO
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SWE
ProceedingsContents
KeynoteLectures|inpresentationorder
SamardzicI,StoiA,KozakD,KladaricI,DunerM
Applicationofweldthermalcyclesimulatorinmanufacturingengineering...............................................................15
GhoshA,HlochS,ChattopadhyayaS
Selectionofappropriatemovingheatsourceshapeofsubmergedarcweldingprocess.........................................614
MldkovL
Knowledgeworkersinmanufacturingsector..........................................................................................................1518
SennarogluB,enS
IntegratedAHPandTOPSISapproachforsupplierselection..................................................................................1922
RuggieroA,HlochS
Methodtodeterminetheanalyticalapproximatedescriptionofnonsteadyfluidfilmforce
influidfilmbearings................................................................................................................................................2326
KumarS,ChattopadhyayaS,SharmaV
Greensupplychainmanagement:AcasestudyfromIndiansmallandmediumscaleindustry.............................2732
SurzhenkovA,VallikiviA,MikliV,ViljusM,VilgoT,KuluP.
WearResistantSelffluxingAlloyBasedTiCNiMoandCr2C3NiHardmetalParticles..........................................3336
SreenivasanM,BaskaranBV,KachinskiyV,KuchukYatsenkoS.
MagneticallyImpelledArcButtWeldingforManufactureofAutomobileHollowPartsofMassProduction.....3740
RaosP,StojiJ,KalendovaA,MerinskaD,ercerM.
Studyonpolyamide12/claynanocompositesbymeltintercalationprocess......................................................4143
RegularSection|inalphabeticalorder
AhnE,ChangDS,PargSC.
SimulationbasedLayoutDesign...........................................................................................................................4448
AtmacaA,TrkbaOS,ErdinME,AykulH.
ElastoplasticStressAnalysisofSteelFibreReinforcedAluminumMetal
MatrixCompositePlates.........................................................................................................................................4952
CelovicS,ManeskiT,VuhererT,TipsarevicM,ZrilicM.
ExperimentalandNumericalAnalysisOfFoldablePlasticPackagingBucklingFailure............................................5355
CucllariF,CiniM,GabetaA.
TheImpactofHumanResourcesManagement1onthePerformanceof
SmallandMediumEnterprisesinAlbania...............................................................................................................5658
DavidoviN,MiloP,JojiB,Blagojevi,MiloM.
JetTabandDomeDeflectorTVCinSolidRocketMotorMathematicalModelandTestComparison....................5963
DuplakJ,OrlovskyI.
TheComprehensiveComparisonoftheSelectedCuttingMaterials
withStandardISO3685inMachiningProcessofSteelC60....................................................................................6467
FekoP.
AManWhoReallyLovedThisWorld(InMemoryofprof.Feko)..........................................................................6869

HatalaM,UngureanuN,MichalikP,DuplkJ,Olexa,KormoM.
InfluenceofFactorsofPlasmaCuttingonSurfaceRoughnessandHeatAffectedZone.........................................7073
JavadiY.
UsingLCRUltrasonicMethodToMeasureResidualStressesThroughThicknessofDissimilarWeldedPipes.........7479
JavadiY,BahmanA.
MeasurementofThroughThicknessResidualStressesinStainlessSteelWeldedPlateUsingUltrasonic
LongitudinalWaves.................................................................................................................................................8084
KadnrM,RusnkJ,ValekJ,KunerovM,TklyP.
TribologicalFeaturesofJournalBearingsMadeofBimetallicAlloy........................................................................8588
KejvalJ,HencP,MllerM,ChocholouP.
MultimediaSupportinSubjectMaterialScience....................................................................................................8990
KnapkovL,HusrJ,OravecP.
HighStrengthFiberinPolyvinylButyralMatrix......................................................................................................9193
KneeviS,SigurnjakL,DusparaM.
ManufacturingTechnologiesinRepublicofCroatia................................................................................................9496
KushanMC,UnalirT,GodeE,EkinciH.
ANewDesignForWirelessEddyCurrentTestingProbe&ItsApplicationsForAircrafts.......................................9799
LazrI.
VerificationofSequentialPatternsinProductionUsingInformationEntropy....................................................100106
MahdiAM,SedmakAS,PetrovskiB,TatiUS,SedmakSA,DjurdjevicAA.
QualityAssuranceofaLargeWeldedPenstockManufacturingbyMeansofFullscaleModelTesting.............107108
MilosevicM,MitrovicN,SedmakA,ManojlovicD,MomcilovicN,MileticV.
ProcedureDevelopmentforStandardizedToothCavityPreparationforinVitroResearchPurposes...............109112
MiloP,DavidoviN,JojiB,Blagojevi,MiloM.
6DOFThrustVectorControlTestStandBasedonStewartPlatformDesign......................................................113121
ModrkV,MartonD,BednrS.
ComparisonofComplexityIndicatorsforAssessingGeneralProcessStructures................................................122125
MllerM,ChotborskR.
UnusualPossibilityResearchofWearResistanceIncreaseinSphereofSoilProcessingTools...........................126131
NauparacDB,PriDH,MiloM.
ElectroHydraulicSystemfortheSimulationofDynamicBehaviourofRocketEngineFlexible
NozzleThrustVectorControl.............................................................................................................................132136
PodornyT,BudzyG,RzepkaJ.
LaserFeedbackSystemforAccurateSubMicrometer........................................................................................137140
PrakashA,GorvendraS.
ElectricalDischargeMachiningofHighSpeedSteelUsingBothLiquidandGasDielectric.................................141148
RadvanskaA.
TextileRecoveryfromSrapRubberTires............................................................................................................149150
RakonjacIM,BudimirSJ,JariMS,BudimirNJ.
ManufacturingcostofShellandTubeHeatExchangerswithparalelHelicalTubeCoils....................................151154
ShankarR,ManivannanA,VijayakumarD.
EffectofFlyAshParticlesontheMechanicalPropertiesandMicrostructureonCompacted
MagnesiumReinforcedWithSiCParticles...........................................................................................................155162
XI
ShirvaniN,RuizR,ShadrokhSh.
PerishableProductSchedulingonSingleMachinewithDeadlines.....................................................................163166
SmiljanicP,SedmakA,EminaD,VegE.
ExperimentalandNumericalStressstrainAnalysisofCompositeBeams...........................................................167169
TemuinT,TozanH,ValekJ,HarnirovaM.
AFuzzyBasedDecisionSupportModelforNontraditionalMachiningProcessSelection.................................170175
TrvnekP,JungaP,VtzT.
CalculationFireandExplosionIndexValuefortheBiogasStation......................................................................176177
TunalioluM,GemalmayanN,OzyilmazE.
TheInvestigationofScoringResistanceonSpurGears.......................................................................................178181
ValekP,CieslarJ,MllerM.
TwoandThreeBodyAbrasionofPolymerParticleCompositeswithFillersonBasis
ofMachiningSplintersfromHardfacingAlloys...................................................................................................182186
YaimliM,TozanH,HlochS.
ATargetTrajectoryEstimationwithDoubleExponentialSmoothingandFuzzyTimeSeries.............................187191
YanarL,TozanH,HlochS.
SelectionofEquipmentforSoftTissueCuttingsUsingFuzzyAHPandFuzzyANP
withaProposedDecisionSupportSoftware.....................................................................................................192197
ZohrevandiS.
QuickSystemsinPlanningandProjectManagement:AStructuredApproachforDevelopingaNewProject...198203
VclavkV,DvorskT,DirnerV,DaxnerJ,ValekJ,KunerovM.
RecycledPolyurethaneFoamasNewFillerinRestorationMortars....................................................................204208
Keynotelecture|Requested
DurakbasaN,BauerJ,BasG.
DevelopmentsinHighPrecisionMetrologyforAdvancedManufacturing.........................................................210215
XII
KeynoteLectures|
inpresentationorder|
"Ifweknewwhatitwasweweredoing,itwouldnotbecalledresearch,wouldit?"
AlbertEinstein
Contents lists available at www.icmem.tk
Manufacturing Engineering & Management

TheProceedings
Application of Weld Thermal Cycle Simulator in Manufacturing

Engineering
IvanSamardi1AntunStoi2DraanKozak1IvicaKladaric1MarkoDuner3
1
MechanicalEngineeringFacultyinSlavonskiBrod,UniversityofOsijek,Croatia
2
UniversityofAppliedSciencesinSlavonskiBrod,SlavonskiBrod,Croatia
3
UniversityofRijeka,Croatia
ARTICLEINFO:
Category:Application
Received:21August2012/Revised:24September2011/Accepted:3October2012
Keywords:(incausalorder)
Abstract:
PWHT
SmitweldTCS1406
T/PP91
Weldthermalcyclesimulation
Weldability
Thepaperpresentsapplicationofweldthermalcyclesimulatorforinvestigationsanddatapredictionsafter
welding process and post weld heat treatment of base material. Along with basic description of thermal
cyclesimulatorSmitweldTCS1406andinfluenceofweldthermalcycleonmechanicalpropertiesandmicro
structure of base metal, the authors provided some practical data obtained on specimens after thermal
simulation. This approach is often used for acceleration of weldability investigations combined with
additional investigations (e.g. hardness and toughness determination, micro structure investigation, etc.)
and other investigations (e.g. post weld heat treatment, casting, hot metal forming, etc.). With weld
thermal cycle simulator it is possible to reduce duration and costs of production (e.g. investigations at
PQR/WPAR,PWHT).
Citation:SamardiI,etal.: Applicationofweldthermalcyclesimulatorinmanufacturingengineering,2ndInternationalConferenceManufacturingEngineering&Management2012,
(2012),p.15,ISBN9788055312163
INTRODUCTION
Simulationofthermalcycleofbasemetalindividualpoint
is a laboratory method suitable for weldability
investigations.Simulationsofthermalcycleofbasemetal
individual point are followed by investigations on
specimens, e.g. hardness and toughness testing, tensile
test and investigations of micro structure. This method is
suitable for investigations in different production
processes, in which thermal cycle at heating and/or
cooling has significant influence on product quality.
However,themostimportantapplicationofthismethodis
in investigations of base metal weldability at single pass
and multi pass welding. Depending of requirements for
weldability investigations,itis possibletoperformsingle
cycle or multicycle weld thermal cycle simulation and
appropriate mechanical testing or other investigations. It
gives relatively fast information, which can accelerate
process of obtaining WPAR/PQR (Welding Procedure
Approval Record / Procedure Qualification Record) and
reduce costs of welding process qualification. Description
ofweldthermalcyclesimulationmethodandpresentation
ofsomeresultsafterexperimentalworkgiveopportunity
for some other application of this method, beside
applicationatweldabilityinvestigations.
a)
b)
Fig.1Dimensionsofthermalcyclespecimensaccordingto
SmitweldTCS1405method,inthecaseofindirectcooling
(a)andinthecaseofindirectandadditionaldirectcooling
bywater(b).1
Thermalcyclesimulationmethod
Fig.2Dimensionsofthermalcyclespecimensaccordingto
theThermorestorWmethod.
Thermal cycle simulation method is an experimental

method developed mostly for weldability investigations.
There are several laboratory devices for thermal cycle
simulation (Smitweld, Gleeble, Thermorestor). Figuration
and dimensions of probe for thermal cycle, detail of
setting the probe in simulation device, and scheme of
execution unit for simulation of thermal cycle are given
below. Thermo couple setting by capacitor discharging
method on each specimen followed after preparing
specimens for thermal simulation (Figure 1). Specimen
was inserted in jaw of block for fixation (position 6 on
Figure 4) and stationary sensor was set for dilatation
measurement(position4onFigure5).
Fig. 3 Specimen for thermal cycle simulation by the

Gleeblemethod.
I. Samardi et al.
Application of Weld Thermal Cycle Simulator in Manufacturing Engineering
meansofweldingcurrentandvoltageandweldingspeed).
Figure 6a shows Smitweld TCS 1406 before thermal cycle
simulation and Figure 6b during rapid heating by electric
resistance system. After thermal simulation, specimens
were prepared for next investigation (e.g. hardness
measurement, toughness testing, metalography
investigations).
2
8
9
7
10
a)
Fig. 4 Execution unit on simulator of thermal cycle type

SmitweldCTS1405.1where1Basescrewwithbolt,2
Pipeconnectorsforindirectcooling,3Waterflowcanal
for indirect cooling, 4 Dilatometer porter and
temperaturesensor,5Basescrewforjaws,6Jawblock
for fixation, 7 Contraction screw for direct cooling
application, 8 Pipe connectors for direct cooling, 9
Directcoolingblock,10Currentcable
6
b)
Fig. 6 Detail of simulation of test probe on simulator of
thermal cycle type Smitweld CTS 1405 (a specimen
before and after thermal simulation, b specimen during
thermalcyclesimulation).
Weldthermalsimulationcanbeperformedassinglecycle
ormulticycle.Figure7ashowsanexampleofsingleweld
thermalcyclesimulationandFigure7bshowsdoubleweld
thermal cycle simulation. Besides temperaturetime
relationship during heating and cooling, it is possible to
monitorthetemperaturedilatationrelationship,whichis
veryimportantinmaterialsscience.
Fig. 5 Position of dilatometer, thermocouple and gas

protection. 1, where: 1 Probe, 2 Thermocouple, 3
Station dilatometer sensor, 4 Movable dilatometer
sensor,5Micrometerscrewfordilatometerregulation,6
Gasprotectionunit.
Sometimes there is a need for gas shielding during
simulation (e.g. during precise dilatation measuring and
very sensitive materials on air influence on elevated
temperatures),inthecaseofwhichthegasprotectionunit
isset(position6onFigure5).Afterconnectingallsensors
(for temperature and dilatation), very rapid heating and
cooling follows in controlled conditions (determinedstart
temperature,heatingandcoolingrate,peaktemperature,
cooling time between 800 and 500 C). The thermal
simulation process is monitored by a computer and all
data are available after simulation for further processing
andapplication.Inthisway,controlledheatinputinbase
materialisappliedanditispossibletoexpectverysimilar
effect during real welding in workshop in case of
controlled welding parameters (heat input achieved by
Fig.7aSingleweldthermalcyclesimulation;temperature
timeandtemperaturedilatationrelationship.2
I. Samardi et al.
BasedonFouriersdifferentialequation,thecoolingrateis
derived at determined temperature for 2 and 3
dimensional heat flow model. 36 Cooling rate (w) at
temperatureTfor2dimensionalheatflowmodel:
T T0 3 2 ,oC/s (6)
dT
w
2 c
Eef2
dt T
Cooling rate (w) at temperature T for 3dimensional heat
flowmodel:
T T0 2 ,oC/s
dT
w
2
Eef
dt T
(7)
where:
To...preheatingtemperature,oC
...thickness,mm
...thermalconductivity,W/(mmC)
c...specificthermalcapacity,J/(kgK)
t...time,s
v...weldingspeed,mm/s
q...heatflow(q=UIl),W
l...arcweldefficiency,
Therefore, 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. An example of that influence is
evident on Figure 8, showing TTT (TemperatureTime
Transformation) diagram for 10CrMo910 steel, which is
very often used in steam boiler components production.
This type of investigation is very expensive and time
consuming, but it is very valuable for modern materials
during weldability investigations and preparation of
weldingprocessqualificationdocuments.Itisalsopossible
toimprovequalityofexistingdocuments,ifthesedataare
availabletoweldingengineers.Inthatcase,thereliability
of weldments will be improved, and the weld thermal
cycle simulation is cost effective. At some welding
productswithincreasedriskoffailure(powerplants,LPG
andLNGtanks),contributiontoqualityandreliabilitycan
significantlyreducethefailurerisk.
Fig. 7b Double weld thermal cycle simulation;

temperaturetime
and
temperaturedilatation
relationship.2
The heat input and cooling conditions have crucial
influenceonmicrostructureandmechanicalpropertiesof
base material and welded joint. There are many
mathematical solutions derived from Fouriers differential
equation for heat conduction, which determine
relationship between welding parameters, physical and
geometric variables on the one side, and cooling time
(cooling rate) on the other side. For the selected heat
input,itispossibletocalculateborderthicknessbetween
2 and 3dimensional heat flows at arc fusion welding
(equation 1). If the border thickness (gr calculated
thickness) is over real thickness at construction, 2
dimensional heat flow model has to be used (high speed
moving line energy source at thin plate). Otherwise, 3
dimensional model will be used (high speed point energy
sourceonverythickplate).[36]
q
v
1
1
(
)
2 c 500 To 800 To
gr
mm
(1)
Incaseof2dimensionalheatflow,theheatinputcanbe
determinedbyequation2and3.[36]
Eef
,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
500 To

1

800 To
,s(3)
Incaseof3dimensionalheatflow,theheatinputcanbe
determinedbyequation4and5.36
E ef
q U I l
v
v
t8/5
2 t8 / 5
1
1
500 To 800 To
,J/mm
,s
Eef
1
1
2 500 To 800 To
(4)
(5)
Fig.8Influenceofcoolingtimeonmechanicalproperties
of10CrMo910steelafteraustenitisationandcoolingat
differentcoolingtime.7
I. Samardi et al.
AfterweldingofT/PP91steel,itwasnecessarytoperform
PWHT at 750 770C (Figure 11), while investigating the
influence of PWHT at that temperature. Figure 12 shows
micro structure of base material and Figure 13 shows
microstructure of fine grain HAZ before PWHT (a), after
PWHT(b).
Investigationonspecimensafterweldthermal
cyclesimulationinHAZ8
HAZregioninweldedjointisnarrowandmaterialsinthe
HAZ are heterogeneous. Many different microstructures
arise in HAZ under the influence of weld thermal cycle.
This paper analyzes fine grain HAZ of T/P91 steel, as this
HAZ region is the most problematic due to creep in
practical application. After weld thermal cycle simulation
of P91 steel (Figure 9), martensite start and martensite
finish temperature are determined after heating and
cooling under controlled conditions, within the regime
shownonFigure10a.Thefollowinginputdatawereused
forweldthermalcyclesimulation(Figure10a):Preheating
temperature:T0=200C,Heatingspeed:150C/s,Maximal
temperature: Tmax = 975C, Holding time on maximal
temperature:0,5s,Coolingtimebetween800and500C:
t8/5=20s,Durationofthesimulation:tfinish=300s.
T [C]
T [C]
1400
1200
1000
T/P91
A
A
T/P91
T/P91
750 - 770C
600
max.
300C
400
(a) 0
B - SMAW or SAW
process
T/P91
800
200
A - TIG process
200C
slow
cooling
till
80 100C
min. 1 h
PWHT
preheat interpass
temp.
temp.
T [C]
T [C]
1400
1200
1000
T/P91
T/P91
T/P91
750 - 770C
600
max.
300C
400
200
PWHT
Fig. 12 Microstructure of base material (light microscope

1000)
Fig.10Weldthermalcycle(a)anddilatation(b)ofsteel
T/PP91inordertodeterminemartensitestartandfinish
temperature.
Fig.13aMicrostructureoffinegrainHAZ(lightmicroscope
1000);beforePWHT
200C
preheat interpass
temp.
temp.
slow
cooling
till
room
temp.
Fig. 11 Basics of welding technology of T/P91 to T/P91;

thickmaterial(a),thinmaterial(b).
a)
b)
(b) 0
B - SMAW or SAW
process
T/P91
800
Fig. 9 TTT diagram of P91 steel with chemical

compositions
Influence of weld thermal cycle and dilatation curve is
showninFigure10b.Startoftransformationofaustenite
intomartensite(MS)is405Candfinish(MF)is325C.
A - TIG process
I. Samardi et al.
REFERENCES
[1] Samardi, I., Stoi,A. Ispitivanje ovisnosti tvrdoe i
radnje loma o vremenu hlaenja t8/5 nakon
simulacije jednoprolaznog zavarivanja. asopis
Zavarivanje36(1993)1/2,255258.
[2] Duner, M. Disertation: Cooling time influence on
hardnessandtoughnessofmicroalloyedsteels.FSB,
Zagreb(Croatia),2004.
[3] StahlEisenWerkstoffblatt88/1993.
[4] Samardi, I.; Galovi, A.; Galovi, M.
Nestacionarnost
temperaturnih
polja
kod
zavarivanja.asopisZavarivanje36(1993)6,211217.
(Croatia)
[5] Lukaevi, Z.; Samardi, I. Primjedbe na raunanje
toplinskog inputa kod REL postupka zavarivanja
sitnozrnatihvisokovrstihelika.asopisZavarivanje
31(1988)2,8191.(Croatia)
[6] Samardi, I.; Stoi, A. Three dimensional
temperature field didtribution during welding. 4th
InternationalConferenceonProductionEngineering
(CIM).Opatija12/13VI,1997.(Croatia)
[7] SeyffarthMayerSchaff,GrosserAtlasSchweissZTU
Schaubilder,DVS,Dusseldorf,1992.
[8] Vuherer, T., Gliha,V., Milovi, Lj., Duner, M.,
Samardi, I. Instruction of welding and review of
steels for power plant equipment and possibility of
using haz simulation in order improve weld joint
quality. Welding conference, Slavonski Brod, 2010.
(Croatia)
Fig.13bMicrostructureoffinegrainHAZ(lightmicroscope
1000)afterPWHT
HardnessresultsonFigure15showtheinfluenceofPWHT
infineHAZafterweldthermalcyclesimulation.
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. 14 Results of Vickers hardness measurement before

andafterPWHT.
CONCLUSION
This paper presents description of Smitweld TCS 1405
weld thermal cycle simulator, which is very suitable for
accelerated investigation of weldability and influence of
PWHT on weldment properties. It presents relationship
between cooling time at weld thermal cycle simulating
parameters and mechanical properties of weld joint in
heataffectedzone(HAZ).Martensitestartandmartensite
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
exampleofapplicationofweldthermalcyclemethod.The
resultsconfirmstronginfluenceofPWHTonhardness.

TheProceedings
Selection of Appropriate Moving Heat Source Shape of Submerged

Arc Welding Process
AniruddhaGhosh1SergejHloch2SomnathChattopadhyaya3
1
GovtCollegeofEngg&TextileTechnology,Berhampore,WB,India,Email:agmech74@gmail.com
FacultyofManufacturingTechnologies,andTUKEwithaseatinPreov,08001Preov,Slovakia,Email:sergej.hloch@tuke.sk
DeptofME&MME,ISM,Dhanbad,India,Email:somuismu@gmail.com
2
3
ARTICLEINFO:
Category:OriginalScientificPaper
Received:10March2012/Revised:30October2012/Accepted:11November2012
Gaussianheatdistribution
Ovalheatsourceshape
SubmergedArcWelding
Abstract:
Anattemptismadeinthispapertofindouttheanalyticalsolutionofthethermalfieldinducedinasemi
infinitebodybyamovingheatsourcewithGaussiandistributionbyselectingappropriateinsidevolumefor
submerged arc welding process. It was revealed that for heat input of SAW process best suitable heat
sourceshapewasoval.
Citation:GhoshA,etal.SelectionofAppropriateMovingHeatSourceShapeofSubmergedArcWeldingProcess,2ndInternationalConferenceManufacturingEngineering&Management
2012,(2012),p.614,ISBN9788055312163
INTRODUCTION
dissipation of rear and front ellipsoid. Fachinotti, V. D.,et
al.[11]proposedasemianalyticalsolutionwhichwasable
to overcome the aforesaid limitations. Nguyen et al. [26]
again described an approximate analytical solution for
double ellipsoidal heat source in finite thick plates. Their
approximate solution can be directly used for simulation
of welding of finite thick plate without the need for
applying the mirror methodas required in a semiinfinite
body.Itisaneffectivetoolforfindingthermalstressand
microstructure modeling. Many problems of welding
encountered in practice involve complicated geometries
with complex boundary conditions or variable properties,
and cannot be solved analytically. In such cases,
sufficiently accurate approximate solutions can be
obtained by computers using numerical methods.
Ravichandran et al. [31] developed a model of
temperature distribution during circumferential arc
weldingofsphericalandcylindricalcomponentsusingthe
finite element method and got very good results.
Employing many simplifying assumptions in the
mathematicalmodel,Chandra[9]describedtheextension
ofRosenthalsmethodfortheestimationofthermalfield
in a pipe with a mobile heat source. Many researchers
gave importance on experimentations for finding out
temperature distribution of welded plates. Akkus (2009)
investigatedtheeffectofsheetthickness,currentdensity
on speed of cooling and distribution of temperature in
resistance spot welding by experiment. In this work, it is
found thicker sheets have higher temperatures in weld
zone. Heat generation in welding zone was affected by
current density and sheet thickness. Veenstra et al. [34]
measured temperature between electrodes for RSW by
applying thermal method and Bentley et al. [4]
investigated temperature distribution in RSW by applying
metallographicmethod.Kermanpuretal.[20]investigated
experimentallytemperaturedistributionofGTAWprocess
forbuttweld.Maheshwarietal.[23]usedthermocouples
to measure temperature at different locations of GMA
welded plates. Temperature readings are taken in every
10secondsintervalandtemperatureprofilearegenerated
for GMAW process which maybe helpful to optimize the
GMAW. In spite of more laborious and time temperature
distribution obtained by experiment has some
Several critical input variables e.g. current, voltage,

electrodediameter,travelspeed,wirefeedrate,stickout
and the like are involved in submerged arc welding.
Temperature distribution during welding depends on
theseweldingprocessparametersasheatinputisfunction
of these parameters[16].The shape of heat distribution
changes with variation of input parameters of SAW
process[13].Studyoftemperaturedistributionofwelded
plates is very essential for designing submerged arc
welding joint [14].An attempt of development of
mathematical model of travelling heat source was made
more than fifty years ago. After that, lots of research
works have been continuing on this area. Initially two
dimensionsurfaceGaussianheatsourcewitheffectivearc
radius was adopted to find out temperature distribution
on welded plates and weld pool geometry [10]. This
solution was an improved version of estimation
temperature distribution near heat source area in (x,y)
plane but this solution is felt to find out temperature
distribution along Z direction. However this attempt
indicated new direction for finding out temperature
distribution on weldedplates.Thenananalyticalsolution
for transient temperature distribution for welded joint
based on similar Gaussian heat distribution but different
distribution parameters was introduced [19].These
researches [10,19] are still limited to 2D heat source, so
these solutions are felt to describe the effect of
penetration. Recently this shortcoming has been
overcomebyconsidering3Dheatsource.Toestimatethe
temperature of the welded joints with deeper weld bead
penetration, [15] first described 3D double ellipsoidal
moving heat source and calculated threedimensional
temperaturedistributionthroughfiniteelementmodeling
which could overcome the shortcoming of the two
dimensionalGaussianmodel.Nguyenet.al.[25]presented
ananalyticalsolutionoftransienttemperaturedistribution
of a semiinfinite body subjected to three dimensional
heat density of semiellipsoidal and double ellipsoidal
mobile heat source. Very good agreement between
predicted and measured temperature distribution data
achieved assuming double ellipsoidal heat source. But
there are still some limitations of this analytical solution,
i.e. this solution is valid only for identical radii and heat
Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process
by infrared thermometers (OMEGA SCOPE OS524E,

temperature range 2482 , accuracy is 1% rdg or 2
which ever is greater, resolution 1 ,response time
10ms).
advantages.Researchers [11,25,26] investigated analytical

solution of thermal field based on heat conduction,
without considering heat lost through convection and
radiation.Butpracticallythethreemodesofheattransfer
occur in welding process. Gutierrez and Araya [17]
conducted the numerical simulation of the temperature
distribution generated by mobile heat source by the
approach of control volume. Here convection and
radiationeffecthavebeenconsidered.Bianacoetal.[5,6]
numericallysolvedthetwoandthreedimensionalmodels
for evaluating transient conductive fields due to moving
heatsource.Biancoet.al.[6]investigatedtransientthree
dimensional temperature distribution numerically by
COMSOL Multiphysics 3.2. Radiation and convection
modesofheattransferfromworkpiecesurfacesaswellas
variablethermophysicalpropertiesaretakenintoaccount.
Theyfoundthatsurfaceheattransferstronglyaffectedthe
temperature distributions in the workpiece. Assuming
constantthermalpropertiesofmaterial,OhringandLugt,
[27] considered radiative heat transfer, evaporation, and
viscous stress to find out temperature distribution.
Mundra et al. [24] considered specific heat and thermal
conductivity values for solid and liquid metal only. From
the above, it is clear that heat transfer mechanism in a
molten pool is extremely complex and its physics is not
well understood, Biswas, and Mandal , [8] analyzed a
numerical model with the aid of the finite element
packageANSYSforsinglepasssinglesidessubmergedarc
weldingofsquarebuttjointsandthedistortionofwelded
joint was determined. In their study, heat lost through
natural heat convection is considered. Sabapathy
et.al.[32,33]and Klobcar et.al[21]attempted to find out
thermal field on welded plates for MMA welding process
consideringflatterandmoreevenlydistributedheatthan
Gaussian and found excellent comparison with measured
data.Ghosh et.al.[12,13] investigated heat source shape
forsubmergedarcweldingprocees.Buttheirinvestigation,
till near about 10% error in prediction of transient
temperature distribution was found. In this 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
submergedarcweldingprocess.
Fig. 1 Representation of axes and identification of few

points(P1,P2,P3,P4)wherereadingoftemperaturewas
taken
Thejobiscutatthreesectionsofweldedplateswhenflux
has been used. The samples are prepared by standard
metallographic process and the average values of the
penetration, reinforcement height are measured using
digital venire caliper of least count 0.002 cm. Table1
depicttheweldparametersofSAWconsideredinpresent
work. The measured values of weld dimensions and
correspondingweldingconditionsaredescribedinTab.2.
Tab.1ChemicalcompositionofCMnsteelworkpiece(in
%)
Mn P
Cr
Ni
Mo
Cu
Al
0.18 0.36 1.58 0.023 0.027 0.06 0.03 0.01 0.04 0.05
The welding parameters were recorded during actual

welding to determine their fluctuations, if any. The slag
was removed and the job was allowed to cool
down.Temperatures are recorded at different points of
the welded plates (as shown in fig.1) except welding line
JobNo.
Voltage
(V)
Current
(A)
TravelSpeed
(cm/min)
Penetration
(mm)
Reinforcement
Height(mm)
BeadWidth
(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
6.70
3.72
6.69
8.26
5.28
4.58
6.60
7.78
2.38
2.34
3.16
2.76
1.00
1.78
2.25
1.94
17.96
21.90
21.00
30.92
13.94
20.12
15.90
22.66
Material Properties: In the present analysis, CMn mils

steel has been used. Table3 shows the temperature
dependent material properties (Mahapatra et. al. (2006))
used for the transient heat transfer and HAZ
analysis.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.Intheliterature,modelsforbothconductionand
convection are available. From the literature survey it is
clearthattheheattransfermechanisminamoltenpoolis
extremelycomplexanditsphysicsisnotwellunderstood.
Althoughsomeprogresshasrecentlybeenmadetowards
a proper modeling of convective heat transfer, these
efforts are still directed towards a proper modeling of
convective heat transfer, these efforts are still directed
towards simple cases. The various material properties of
metals in the molten state are also not authentically
established. In arc welding, except for a small volume of
metal,mostportionsofworkspecimenremaininthesolid
state. Therefore a three dimensional thermal model was
consideredtoanalysistheheattransferandtheresulting
temperaturedistribution.
MEMCO semi automatic welding machine with constant

voltage,retifyertypepowersourcewitha1200Acapacity
was used to join CMn steel plates 30152cm.ESAB
SA1(E8),0.315cm diameter,coper coated electrode in coil
from and ESAB brand ,basic fluoride type granular flux
used.Theexperimentswereconductedasperthedesign
matrixrandomlytoavoiderrorsduetonoisefactors.Two
piecesofCMnsteelplateswerecutandVgrooveofangle
60o as per the standards were prepared. The chemical
compositionofworkpiecematerialisdescribedinTable1.
0.1cmrootopeningwasselectedtojointheplatesinthe
flatpositionkeepingelectrodepositiveandperpendicular
totheplate.Thejobwasfirmlyfixedtoabaseplateand
thenthesubmergedarcweldingwasfinallycarriedout.
Sn
Sl.No.
Tab.2Observedvaluesforbeadparameters
EXPERIMENTALMETHOD
A.Ghosh et al.
Ghosh A. et al.
Temperature
( )
Thermal
conductivity
(W/mK)
Specific
heat(J/kgK)
Thermal
expansion
coefficient(10
6
/
Young
modulus(GPa
)
Poissonratio
Tab. 3 Variation of thermo mechanical properties with

respect to temperature of CMn Steel (Mahapatra et. al.
(2006):
0
100
300
450
550
600
720
800
1450
1510
1580
5000
52
51
46
41
37.5
36
31
26
29.5
29.7
29.7
42
450
500
565
630.5
705.5
773.3
1080
931
438
400
735
400
10
11
12
13
14
14
14
14
15
15
15
15.5
200
200
200
150
110
88
20
20
2
0.2
0.00002
0.00002
0.28
0.31
0.33
0.34
0.36
0.37
0.37
0.42
0.47
0.5
0.5
0.5
combinationoftwosemiellipsoidal(onehasmajoraxisaf
and other ar). For this study, combination of semi
ellipsoids is assumed to be an oval shape. These
combination of two semi ellipsoidal shapes was called
double ellipsoidal heat source configuration. In present
study it was found for experiments that shape of weld
poolgeometrywasoval.ForjobB4oftable2,equationof
ovalweldpoolgeometrywas
1(asshowninfig.3).
So ,heat source shape for this study was assumed as an

ovalshape(asshowninfig.3)whoseequationis
.
Assumption made in thermal model: In developing the

thermal model, an attempt has been made to
accommodate the actual welding conditions as far as
possible. However, the following have been assumed in
thethermalmodeloftheweldingprocess.
Density was remains constant and did not change
withtemperaturechange.
All other thermal properties ware considered as a
functionoftemperature.
Convective heat lost through all surfaces of welded
plated.
Heatlossduetoradiation.
Heat Source Model: The heat source model, defining the
distributionoftheheatinputduetotheweldingarc,has
animportanteffectontheheatdistributionpatterninthe
vicinity of the weld zone. It is in this region where the
fusion zone and the heat affected zone are formed. It is
therefore important to study the effect of heat input
distribution on the size and shape of these zones. For
analyzingtheheatflowpatternonweldedplates,theheat
input can be treated as distributed heat source. In the
literature, many heat source distributions through
Gaussian manner of inside volume ellipsoidal, double
ellipsoidal, double central conicoidal, bell (2D), was
described(Ghosh et. al.(2011). In present work ,oval heat
source considered and found most suitable heat source
shape.It was found from literature (Nguyen
et.al.(1999),Ghosh et. al.(2011)that most suitable heat
sourceiscombinationoftwosemiellipsoidalshapes.Semi
majoraxisofoneoftheseellipsoidswasafanotherwasar
asshowninfig.2.
Fig.3 Comparison of ellipse (
1) and oval
1shapes.It was found from

.
.
experimentthatshapeofweldpoolgeometryisovaland
equation of weld pool geometry for B4 job (of table2)
is
.
.
1,wherem=0.3forthisstudy
(1)
Where af+ar=a= semi major axis, b=semi minor axis,
c=another semiprincipal axis of an ellipsoid whose
1 .It can be realized from
equation is
fig.3.
LetusconsiderafixedCartesianreferenceframex,y,zas
shown in fig. 1. Initially proposed a oval heat source (as
showninFig.2,3)inwhichheatisdistributedinaGaussian
manner throughout the heat sources volume. The heat
density q(x, y, z) at a point(x, y, z) with in oval shape is
givenbythefollowingequation:
q(x,y,z)=A
(1)
[WhereAisGaussianheatdistributionparameteranda,b,
c,mareovalheatsourceparameters]
IfQ0isthetotalheatinput,then
2Q0=
orA=
x, y, z
Q0
(2)
Ovalshapeheatdistributionequationis:
q(x,y,z)=
Q0
(3)
Here,Q0=IV;
(4)
V,I,=welding voltage, current and arc efficiency
respectively.
Arc efficiency is taken 0.9 for submerged arc welding
process.Analyticalsolution:Transienttemperaturefieldof
ovalshapeheatsourceinasemiinfinitebodyisbasedon
Fig.2Doubleellipsoidalheat
Source described by Henwood et al.(1988).Double
Ellipsoidal Heat Source Configuration i.e. it is a
due to the point heat source dQ at time t ;( x, y, z) =

locationofinstantpointheatsourcedQattimet.
Here:
solution for the instant point source that satisfied the

followingdifferentialequationofheatconductionoffixed
coordinates (Nguyen et al., 1999).Moving Double Oval
HeatSourceProblem:Letusconsideraheatsourcelocated
atx=0attimet=0moveswithconstantvelocityvalong
thexaxisandheatemittedatapoint(x,y,z)ataninstantt
bytheovalheatsource.Mathematicalexpressionofoval
heatsourceis
q(x,y,z)=
Q0
I dt
I dt
a=
dx

(x)+

](x)
(15)
dt
Similarly,b=
c=
(16)
(17)
(18)
(19)
Values A, B, C can be measured from weld bead

geometry,B=halfofthebeadwidth,C=PenetrationandA=
half of the major axis of oval shape=1.15B(
experimentallyfoundi.e.throughweldpoolmeasurement
for submerged arc welding process). Experimentally
measuredvaluesA,B,Careappliedtofindoutthevalues
temperature distribution of equation No16.Actually
thermal diffusivity, thermal conductivity, specific heats of
material are changed with change of temperature. So to
getbetterresultsagainapproximatesolutionoftransient
temperaturedistributionhasbeendevelopedconsidering
variation of thermomechanical properties w.r.t.
temperature, which is described below.From equation
No.1to10,itcanbewrittenthat
c
(12)
dT=
Iy
k
Or
Where =thermal diffusivity, c_p=specific heat, =mass

density; t, t =time; dTt=transient temperature change
dy(14)
CalculationofOvalShapeBeadGeometryparameters:
Let the A, B, C are the Oval Shape Bead Geometry
parameters. It has been literature (Goldak and Akhlaghi,
2005),q(A,0,0)=q(0)
=0.05q(0)
(11)
Finally, by assuming the body was initially at the

homogeneous temperature T0, the temperature field is
definedby
T(x, y, z, t) T0= .
(Where, I =f(xvt),whenIx=f(x))
T(x, y, z, t) T0=
x, y, z, t G(xx,yy,z
T(x,y,z,t)= .
z,tt) dt
(10)
Then the temperature induced by the oval heat source

definedbyequationis
Ix has been calculated by applying numerical method

taking appropriate values of integration upper and lower
limit. When heat source is moving with constant speed v
fromtimet=0tot=t,theincreaseoftemperatureduring
thistimeisequivalenttothesumofallthecontributions
ofthemovingheatsourceduringthetravellingtimeas:
(7)
If we assume that the heat has been continuously

generated from t=0 throughout an infinite medium, the
temperature increment at any point (x, y, z) and at any
instantttakestheform
T(x, y, z, t) = .
dz(13)
q x, y, z, t G(xx,yy,zz,tt)dt(9)
=[
Where=k/(c)isthethermaldiffusivity.
Equation (7) gives the temperature increment at point(x,
y, z) and at instant t due to an instantaneous unit heat
source applied at point (x, y, z) at instant t, assuming
the body to be infinite with an initial homogeneous
temperature. Then, due to the linearity of equation (7),
thetemperaturevariationinducedatpoint(x,y,z)attime
tbyinstantaneousheatsourceofmagnitude
q(x,y,z,t)appliedat(x,y,z)attimetis
(8)
q(x,y,z,t)G(xx,yy,zz,tt)
Assuming that heat has been continuously generated at

point (x, y, z) from t=0, the temperature increment at
point(x,y,z)attimetis
Ix=
(6)
Iy =
WhereT=T(x,y,z,t)isthetemperatureatpoint(x,y,z)at
timet,qistheheatsource,isthedensity,cistheheat
capacityandkisthethermalconductivityoftheplatesof
weldedplates.Thefundamentalsolutionofequation(6)is
theGreenfunction,i.e.
G(xx,yy,zz,tt)=
(5)
Iz=
Induced Temperature Field: Heat conduction in a

homogeneous solid is governed by the linear partial
differentialequation
k 2T+q= c
A.Ghosh et al.
Iy
Izdt
/
dT=
Izdt(as
(20)
Ghosh A. et al.
OrFromdataofthermomechanicalpropertiesoftable3
andwiththehelpofMATLAB,relationsbetweenthermo
mechanical properties and temperature have been
developed which are described in table 7.Putting the
mathematicalexpressioninequation20,weget
2.7
1.210
10
0.01
52
0.0035
Iy
Iz dt
Or
0.0675
10
T
T
T
T
0.86 10
T
31.2 10
0.182 T T
Iy
Iz dt
(21)
Comparison of measured and estimated

temperaturedistributionthroughanalyticalsolution
with the help of past history considering different
types of heat source on (25, 15, 0). Here x axis
denotes time and Y axis denotes (TT0),where T0 is
initialtemperatureofbasemetals.
Calculation of a,b,c have been done with the help of

equations 17,18,19.Solution of this equation (equation
21)hasbeencompletedwiththehelpofHornersmethod.
Valueofmisequalto0.2hasbeenassumedforthisstudy.
5.4Considerationofconvection
Heat input (Q0) =Conductive heat flow (

(neglectingradiation)
Let a block of dimension dx, dy, dz, convective heat
transfercoefficienth,
Soitcanbewrittenthat
Heatinput(Q0)=
c
= (1-
So,
,
) = (1-
(as,dz=platethickness=L)
types of heat source on (25, 20, 0). Here x axis
denotes time and Y axis denotes(TT0),where T0 is
= (1-
= (1-
Q0=0.9Q (fromtable8)
d
So, equation can be written in this way when convective

lostisassumed
0.0675
T
31.2
10
10
0.9
0.86
0.182 T
10
T =
Q
I
Iy Iz dt
Calculation of a, b, c have been done with the help of
equations 17,18,19.Solution of this equation(equation
22)hasbeencompletedwiththehelpofHornersmethod.
8

types of heat source on (0, 0, 2 0). Here x axis
denotestimeandYaxisdenotes(TT0),whereT0is
Fig.4Comparisonofmeasuredandestimatedtemperature
distribution through analytical solution with the help of
pasthistoryconsideringdifferenttypesofheatsource.
RESULTSANDDISCUSION
Withthehelpofequation22andliteraturesurvey(Ghosh
et. al.(2011)), transient temperature was calculated and
comparedwithmeasureddatawhichareshowninfig.4.It
wasfoundthatmostsuitableheatsourceshapeisoval.
PredictionofPenetration
Weld bead penetration of a structural steel is the region
heatedfromatmospherictemperature(i.e.,273 )tothe
melting point temperature of welded materials
(i.e.1464 ). Putting these values in the equation (22),
10
CalculatedHAZ
width(mm)thehelpof
equation23
CalculatedHAZ
width(mm)
thehelpofequation22
MeasuredHAZ
width(mm)withthehelp
ofhardnessvariation
ValueofB(mm)
SlNo.
1.2
1.4
1.4
2.0
0.9
1.3
1.1
1.5
1.12
1.33
1.32
1.92
0.91
1.22
1.01
1.56
a=
2.7 10
1.210
Regression coefficient
R2(%)
52
96
99
0.0035
) with the help of
(1
)
0.90
0.90
0.90
0.90
0.90
0.90
0.90
0.90
0.90
0.90
. Similarly, b=
, c=
Let equation of oval Shape heat affected zone boundary

(curve2)Ax2+(By2+Cz2)f(x)=1,whereA,B,Carethe
ovalShapeheataffectedzoneboundaryparameters.
Heat density at the boundary of oval Shape Bead
Geometry=cp(Tmelt T0), where density of welded
material, cp is the specific heat of this material, Tm
melting point temperature of welded material, T0 is the
atmospherictemperature.
Heat density at the boundary of heat affected zone
=cp(ThazT0), where Thaz is the lower critical
temperature(i.e.723 )temperatureofweldedmaterial.
So,
Or,
=
Or,
11
PredictionofHAZwidthinalternativeway
Let, equation of an oval Shape Bead Geometry Ax2+
(By2+Cz2) f(x) =1, where A, B, C are the oval shape bead
geometryparameters.
It has been found from literature [Goldak (2005)] that, q
(A,0,0)=q(0)
0.05 0 .
Tab.6PredictedHAZwidth(s)
1.2
1.5
1.4
2.1
0.9
1.4
1.1
1.5
0.01
data,describedintable3
(Thermal
Temperature
Thermal
2
1/2
( )
diffusivity(m /sec) diffusivity)
0
0.000015
0.004
100
0.000013
0.004
300
0.000010
0.003
450
0.000008
0.003
550
0.000007
0.003
600
0.000006
0.002
720
0.000004
0.002
800
0.000004
0.002
1450
0.000009
0.003
1510
0.000009
0.003
PREDICTIONOFHAZWIDTH
HAZwidthofaCMnsteelistheregionheatedfromlower
critical temperature (i.e., 723 ) to the temperature just
belowthemeltingpointtemperatureofweldedmaterials
(i.e.1464 ).Puttingthesevaluesintheequation(22)HAZ
width(s)canbecalculatedatz=0,x=vt,t=t=traveltimeof
electrodewhicharedescribedintable6.
1.1
1.3
1.3
1.9
0.9
1.2
1.0
1.4
Tab.8 Calculated values of (1
Tab.5Comparisonofpredictedandexperimentalvaluesof
weldbeadwidth
WeldBeadWidth
WeldBeadWidth %error
(mm)
(mm)
(ExperimentalValues) (PredictedValues)
17.96
19.73
9.9
21.90
23.91
9.2
21.00
23.00
9.6
30.92
34.01
10
13.94
15.29
9.7
20.12
22.09
9.8
15.90
17.47
9.9
22.66
24.90
9.9
1
2
3
4
5
6
7
8
1
2
Mathematical Model
Tab.4Comparisonofpredictedandexperimentalvaluesof
penetration
Penetration
Penetration
%error
(mm)
(mm)
(ExperimentalValues) (PredictedValues)
6.70
7.36
10
3.72
4.1
9
6.69
7.34
9.5
8.26
9.08
10
5.28
5.78
9.8
4.58
5.03
9.9
6.60
7.26
9.8
7.78
8.55
9.9
PREDICTIONOFWELDBEADWIDTH
Weldbeadwidthofastructuralsteelistheregionheated
from atmospheric temperature (i.e., 723 ) to the
temperature the melting point temperature of welded
materials(i.e.1464 ).Puttingthesevaluesintheequation
(22), half of weld bead(s) can be calculated at z=0, x=vt,
t=t=traveltimeofelectrode,afterthatmultiplyingbytwo
beadwidth(s),theresultsaretabulatedintable5.
Relation with temperature

thermo mechanical property
Tab.7 Mathematical relation of thermo mechanical

propertiesandtemperature
Sl.No
penetration(s) can be calculated at y=0, x=vt, t=t=travel

timeofelectrode,whicharetabulatedintable4.
A.Ghosh et al.
, ,
, ,
, ,
, ,
,
,
Ghosh A. et al.
As, Tmelt =14640C,Thaz = 7230C, 0

0.05q (0)
andassumingatmospherictemperatureisequalto300C.
Soitcanbewritten,
the hardness values are low and prominent grain growth

(as shown in fig6c) was found at just below the fusion
zone.
a
=1.1224
So,(BB)=0.1224B
Or,HAZwidth=0.1224B
(23)
With the help of table2 and eqation23, HAZ width(s)
havebeencalculatedwhicharealsodescribedintable6.
VALIDATIONOFPREDICTEDDATAOFHAZWIDTH
To validate predicted HAZ width, measurement of
hardnessonweldedzoneandnonweldedzone(asshown
infig.5)andanalysisofmicrostructure(asshowninfig.6)
werecarriedout.
a
Microstructure at the non welded zone (as
shown in fig.5c) of 3000 magnifications for 2.84
kJ/mm heat input. Negligible grain growth
portion.
b
Hardness values are recorded at different grid

junctions of the welded specimen (distance between
twogridpointsisequalto2mm)
b
Microstructureattheweldedzone(asshownin
fig.5c)of3000magnificationfor2.84kJ/mmheat
input.Fewpointsareprominentgraingrowthin
thismicrostructure;thesearethesoftening
portionofweldedzone
Fringeplotofhardvariationofsubmergedarcwelded
plates.Here, HAZ width is equal to 0.156 cm or
1.56mm(forthejobA4,heatinputfortheprocessis
2.84KJ/mm).
Identificationofdifferentportionofsubmergedarc
weldedplates
Fig.5HardnessVariationofweldedplates
Negligible grain growth portion was found form the
analysis of microstructure at the non welded zone(as
shown in fig6a) . But, in few points, prominent grain
growth ware found9as shown in fig6b). These are the
softening portion of welded zone. Microstructure at the
Heat Affected Zone. Here more softening portions were
found w.r.t welded portion (as shown in fig.6c) because
temperature of this portion exceeded from
recrystalisationtemperatureofthemetalforatime.That
is why prominent grain growth ware found. This is the
Heat Affected Zone. It was found by measuring hardness
(as shown in fig.5b,c) that at just below the fusion zone,
Microstructure at the Heat Affected Zone (as

shown in fig.5c) of 3000 magnification for 2.84
kJ/mm heat input. Here more softening portion
w.r.t welded portion. This is the Heat Affected
Zone.
Fig.6MicrostructureVariationofweldedplates
Around1.56mminbothsideatjustbelowthefusionzone
thehardnessvalues(asshowninfig.5b)arecomparatively
low. This low hardness and prominent grain growth
portionistheheataffectedzone(HAZ).Abovedescription
12
provesthatHAZwidth1.56mmfor2.84kJ/mmheatinput
in welding process which compares well with the above
predictedHAZwidthdataasgiveninTable6.
[2] Ali, Y., M., Zhang, L., C. (2005). Relativistic Heat

Conduction. International Journal of Heat Mass
Transfer,4823972406.
[3] Ali, Y., M., Zhang, L., C. (2005) Relativistic Heat
Source,InternationalJournalofHeatMassTransfer,
48,27412758.
[4] Bentley,K,P.,Greenwod,J.,A.,P.Knowlson,P.,Baker,
R.,G.(1963).Temperaturedistributioninspotwelds,
BritWeldJ.,10,613619.
[5] Bianco, N., Manca, O., Naso, V. (2004). Numerical
analysisofTransientTemperatureFieldsinSolidsbya
Moving Heat Source, HEFAT2004,3rd Int.Conf. on
HeatTransfer,FluidMechanicsandThermodynamics,
papernBN2,2124.
[6] Bianco, N., Manca, O., Nardini, S.(2008), Two
Dimensional Transient Analysis of Temperature
DistributioninaSolidIrradiatedbyaGaussianLesser
Source,Proc.ESDA2004582867thBiennialConf.on
EngineeringSystemsDesignandAnalysisJuly1922.
[7] Bianco, N., Manca, O., Nardini, S. ,(2006). Transient
Heat Conduction in Solids Irradiated by a Moving
Heat Source. Excerpt from the Proceedings of
COMSOLUserConference2006Milano.
[8] Biswas, P., Mandal, N., R. (2009). Thermomechanical
Finite Element Analysis and Experimental
Investigation of Single Pass Single Sided
Submerged Arc Welding of CMn Steel Plates,Proc.
IMechE Vol.224 Part B: J.Engineering Manufacture,
627639.
[9] Chandra, U. (1985). Determination of residual
stressesduetogirthbuttweldsinpipes.Trans.ASME
J.Press.Ves.Technol,107,178184.
[10] Eager, T., W., Tsai, N., S. (1983). Temperature fields
produced by traveling distributed heat sources.
WeldingJournal,62(12),346355.
[11] Fachinotti, V. D., Cardona, A. (2008) Semianalytical
Solution of the Thermal Field Induced by a Moving
DoubleEllipsoidal Welding Heat Source in a Semi
Infinite Body. Asociacion Argentina de Mecanica
Computacional1013,15191530.
[12] Ghosh, A.,et.al., (2011),Prediction of Temperature
Distribution on Submerged Arc Welded Plates
through Gaussian Heat Distribution Technique,
Advanced Materials Research, Volumes 284
286,,pp.24772480.
[13] Ghosh,A.,et.al., (2011),Prediction of Weld Bead
Penetration, Transient Temperature Distribution&
HAZwidthofSubmergedArcWeldedStructuralSteel
Plates, Defect and Diffusion Forum Vols. 316317,pp
135152.
[14] Goldak, J., A., Akhlaghi, M., (2005). Computational
WeldingMechanics.Springer.71115.
[15] Goldak, J., Chakravarti, A., Bibby, M., A Double
Ellipsoidal Finite Element Model for Welding Heat
Source,IIWDoc.No21260385.
[16] Gunarajan,V.,Murugan,N.,2002.PredictionofHeat
Affected Zone Charecteristics in Submerged Arc
welding of Structural Steel Pipes. Welding Research,
9498.
[17] Gutierrez, G. Araya, J., G., (2003). Temperature
Distribution in a finite Solid due to a Moving laser
Beam. Proc. IMECE200343545,2003 ASME Int.
Mech.Eng.Congr.,Washington,D.C.November,1521.
CONCLUSION
1.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
thedimensionofbeadgeometry.
2.Transienttemperaturedistributiononweldedplatecan
becalculatedwiththehelpofGaussianOvalshapeHeat
distributiontechnique.
3.In this study, analytical solutions for the transient
temperaturefieldofasemiinfinitebodysubjectedto3
Dpowerdensitymovingheatsource(suchasovalshape
heat source, which is first time attempted in this work)
werefoundandexperimentallyvalidated.Theanalytical
solution for oval shape heat source was used to
calculatetransienttemperaturesatselectedpointsona
mild steel plates which are welded by taking x axis
alongweldingline,originisstartingpointofwelding,y
axis is perpendicular to welding line and zaxis towards
platethickness.Bothnumericalandexperimentalresults
fromthisstudyhaveshowedthatthepresentanalytical
solutioncouldofferaverygoodpredictionfortransient
temperaturesneartheweldpool,aswellassimulatethe
complicated welding path. Furthermore, 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, such as thermal stress,
residual stress calculations and microstructure
modeling.
4.Bead geometry dimensions have been calculated with
the help of analytical solution (described in this paper).
Very good agreement between the calculated and
experimentalvalues.
5.PredictionofHAZwidthhasbeenmadewiththehelpof
three dimension transient temperature distribution
equation. It is also new technique which is not
previouslyapplied.
6.Existence of prominent grain growth provides the
confirmatory evidence of the HAZ softening
phenomenon. In the welded portion, grain refinement
occurs in most of the region due to the heating and
coolingcycleofSAWmethod.Predominantdirectionof
the grain growth is clearly observed from the
photograph of the microstructure. This grain formation
is distinctly revealed in the magnification (50,100) for
theheatinputof2.84kJ/mm.HallPetchequationstates
thestrengthofthemetalistovaryreciprocallywithsize
of subgrain.The similar phenomenon is also revealed in
caseofhardness.Inthecontextofthisequationonecan
say that the hardness of the grain growth portion will
alsomanifestlowervaluesrelatedtohighergrainsizes.
Inthegraingrowthportionoftheweldedregionlonger
grains have been found depicting the chances of
dislocation, slip, low yield strength and low hardness
valuesmeasuredinRockwellscaleB.
7.Validations of calculated HAZ width through analysis of
microstructure changes(comp. Fig.6) and hardness
analysishavebeenmade.Verygoodagreementhasalso
beenfoundforthiscase.
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14

TheProceedings
Knowledge Workers in Manufacturing Sector

LudmilaMldkov1
1
DepartmentofManagement,UniversityofEconomicsPrague,W.Churchilla4,Prague3,13000,CzechRepublic,Email:mladkova@vse.cz
ARTICLEINFO:
Category:ProfessionalPaper
Received:14September2012/Revised:14October2012/Accepted:22October2012
Abstract:
Knowledge
Knowledgework
Knowledgeworker
Managementofknowledgeworkers
Tacitknowledge
Knowledge workers are people who, generally said, think for living [5]. Their work and productivity depend on their
knowledge and ability to learn, even though they work with their hands [27]. Major working tool and asset of
knowledge workers is their knowledge. 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. Due to
the intangibility of tacit knowledge, knowledge workers are difficult to manage. The paper provides the reader with
a review of theoretical literature on knowledge workers and other related topic. Theory is accompanied by examples
from manufacturing organizations. They help to explain role and importance of knowledge workers in organizations.
Citation:MldkovL. KnowledgeWorkersinManufacturingSector,2ndInternationalConferenceManufacturingEngineering&Management2012,(2012),p.1618,ISBN97880553
12163
INTRODUCTION
knowledge is partly subconscious; the worker may not
know about it or may not understand its importance.
Other employees of the organisation have a limited
approach to the knowledge. By Drucker, knowledge
workers often work intellectually, but this is not a rule.
Jack Vinson understands the knowledge worker as every
employee who uses his brain more than his hands.
Knowledgeworkersdependontheirknowledgeandability
to learn, even though they work with their hands [27].
Lowe [13] limits knowledge workers to those with a
university degree. Thomas Davenport [5] sees knowledge
workers as people with high degrees of expertise,
education,orexperience.Davenportsaysthattheprimary
purpose of a knowledge workers job involves the
creation, distribution, or application of knowledge. 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.
However, in practice, organisations in these industries
needtodeployawiderangeofcomplementaryjobswith
varying degrees of intellectual content [4]. Sveiby [20]
takes the industry approach and relates knowledge
workerswithsoftwareandadvertisingfirms.Alvesson[2]
sees knowledge workers as people who work in
knowledge intensive organisations, R&D and high tech
companies.Brinkley,Fauth,Mahdon,Theodoropoulou[4]
conclude that economists often distinguish knowledge
workers based on the investment expenditures in
activities such as education and research and
development. Job content approaches see knowledge
workers as people who do a certain type of job. Alvin
Toffler[22]understandsthetypicalknowledgeworkerasa
scientist, an engineer or a person who operates
sophisticated technology. He states that a knowledge
worker must be able to create and improve his
technological knowledge or manage the technological
knowledge of coworkers. For Robert Reich [19]
knowledge worker is the one who engage in non
standardised problem solving using a range of analytic
toolsoftenabstractinnature.Thekeystotheseworkers
success include creativity and innovation and incorporate
occupations ranging from lawyers to bankers to
Knowledge workers are people who, generally said, think

forliving[5].Theirworkandproductivitydependontheir
knowledge and ability to learn, even though they work
with their hands [27]. Knowledge is a major working tool
andassetofknowledgeworkers.Knowledgeis,duetoits
tacit dimension, of intangible character. The intangibility
of knowledge is responsible for the difficulties managers
face when managing knowledge workers. First, there are
problemswithcontrol.Theprocessofworkofknowledge
workers is hidden. The observer cannot see how a
knowledge worker uses knowledge when working [11].
Knowledge workers often posses knowledge that is not
widely available and even their managers do not have it.
Big portion of this knowledge is of tacit dimension and
cannot be expressed by words, notes, pictures or other
means. When the worker leaves the organisation, his
knowledge is leaving with him. This causes problems
especiallywhenorganisationseesknowledgeworkersonly
as people with high degree of formal education and fails
to see importance of ordinary employees like workers,
people in administration, maintenance people who often
posses tacit knowledge important for their organisation.
As for the methodology, a review of literature on
knowledge workers was done by analysis of literature on
knowledge workers, knowledge and knowledge work.
Method of storytelling is used for the example on how
knowledge worker may be important in manufacturing
organization.
WHOAREKNOWLEDGEWORKERS
Even though there is no common definition of the term
knowledge worker, definitions and approaches to
knowledge workers can be classified into 3 different
groups; conceptual definitions and approaches, data
(industry)drivenapproaches,andjobcontentapproaches
[4]. Conceptual approaches explain the term knowledge
worker from the complex point of view. Employees
importance for an organisation, his style of work with
knowledge, education and other factors are taken into
account.Thefirsttousethetermknowledgeworkerwas
Peter Drucker [6]. Knowledge worker, by Druckers
definition is a person who has knowledge important for
the organisation and is often theonly person who has it;
he can use the knowledge in work. Knowledge workers
15
L. Mldkov
is information with context that provides the basis for

actions and decision making. Nonaka and Takeuchi [18]
define knowledge as justified true belief. For Wiig [29]
knowledgeisthebodyofunderstandings,generalisations,
andabstractionsthatwecarrywithusonapermanentor
semipermanentbasisandapplytointerpretandmanage
the world around us [14]. Knowledge can be classified to
two groups, explicit and tacit [18]. Explicit knowledge is
encoded in organisational formal models, rules,
documents, drawings, products, services, facilities,
systems, and processes and is easily communicated
externallythroughdata[25,1].Tacitknowledgeisstored
in peoples brains as mental models, experiences, and
skills and is difficult to communicate externally [25].
Capturing tacit knowledge and codifying it is one of the
biggest challenges of knowledge management [3, 1]. The
tacit dimension is hidden, subconscious and even an
owneroftheknowledgemaynotbeawareofit.Itissaid
that tacit knowledge creates 90% of knowledge we have.
Transformation of tacit knowledge to explicit is difficult
and often does not lead to good results. The tacit
dimensionofknowledgeisresponsiblefortheintangibility
ofknowledgeworkandspecificsofknowledgeworkers.
HowKnowledgeWorkersWorkwithKnowledge
While working with knowledge, knowledge workers
execute and interlink different knowledge processes.
Among many, three are crucial. They are knowledge
acquisition, knowledge creation and knowledge sharing.
Knowledge acquisition when knowledge workers must
acquire the necessary knowledge before they start to
create values for their organisation. The process of
knowledge acquisition starts in childhood, goes on
through professional training and continues in the
productiveage.Knowledgecreationwhichistheabilityto
create new knowledge, a knowledge worker must have
moreknowledgethatisactuallyneededforthecreationof
thatknowledge[14].Knowledgesharingthatisimportant
for achieving group and organisational objectives and
whichmaybeverytrickyincaseofwhenknowledgeisin
thetacitformandwhenevenaknowledgeworkerwhois
willingtoshareitmayfail.Allthreeprocessesofworkwith
knowledge and the creation of knowledge can happen
simultaneously,oritappearssobecausethehumanbrain
can work very efficiently and quickly. They happen on
differentlevels:
Individual level is a basic level, no group or organisation
canlearnandworkwithknowledgeifitsindividualsdonot
learnandworkwithknowledge.Thequalityandsuccessof
individual work with knowledge depend on talents and
willingnessofknowledgeworkersandontheenvironment
the organisation creates for work with knowledge.
Individual knowledge creation is explained in the SECI
model [18], the model of Ba [16] and the model of
knowledgeassets[17].AsGarcaMuina,MartndeCastro
and Lpez Sez [7] write, individual knowledge is shaped
bypersonalexperiences,throughspaceandtime,caused
by relations with other individuals or generally with the
nature of the environment, and it is processed by the
humanbrain.Groupleveldevelopsinthegroup,anopen
system whose elements are different individuals able to
createknowledgethroughtime.Thegrouplevelcaptures
knowledgefromindividualsandfromhigherlevelsystems,
theorganisationallevelandtheinterorganisationallevel.
Group members share their tacit knowledge through
metaphors, analogies and models; explicit knowledge is
combined through reasoning, dialogue and material
sharing [14]. The organisational level creates rules and
guidelines that influence the level of the group and
individual.Iftheorganisationallevelismanagedwisely,it
researchers to consultants [4]. Kidd [12] identifies

knowledge workers as people who work in design,
marketing, management and consultancy, advertising,
broadcasting, law, finance and research. Nomikos [15]
classifies knowledge workers as a group that includes
scientists,engineers,professors,attorneys,physiciansand
accountants. But he concludes that knowledge workers
are highly qualified and highly educated professionals.
Tomlinson [23] identifies them as managers, people in
technical and professional occupations and associate
professionals.
CHARACTERISTICSOFKNOWLEDGEWORKERS
Asmentionedintheintroduction,knowledgeworkersare
specific group of employees. Yau [30] collects and
summarises ideas of different authors on knowledge
workers.
12
Profession
Applicationof
knowledge
New
breed/class
Continuous
development
Creatingnew
knowledge
Findingexi
sting
knowledge
3
4
5
6
7
8
Credentials
External
controls
10
11
Knowledge
sharing
Social
interaction
Characteristics
statedby
Kellowayand
Barling
Commitment
Characteristics
statedbyKidd
Primary
characteristics
ofknowledge
worker
Characteristics
statedby
Collins
No/Rating
Totalno.of
distinctauthors
stating
characteristics
Tab.1Maincharacteristicsofknowledgeworkers[30]
Knowledge, Material and Tool for Knowledge

Workers
Knowledge is a major tool and source for knowledge
workers.Tobeabletounderstandfullytheproblematicof
knowledge workers, the term knowledge must be
explained. Knowledge itself can be defined and
understood in many ways. This article gives space for
mentioning only some of them. For example Woolf [28]
sees knowledge as organised information used for
problem solving. Tobin [21] understands knowledge as
information plus intuition and experience. Turban [24]
writesthatknowledgeisinformationthatisorganisedand
analysed to become legible and usable for problem
solution and decision making. Veber [26] defines
knowledgeasachangingsystemwithinteractionsamong
experience, skills, facts, relations, values, thinking
processesandmeanings.Kanter[10]saysthatknowledge
16
L. Mldkov
positively influences knowledge creation in group and

individual levels [14]. Interorganisational level resembles
thepreviouslydescribedlevels.Itisstronglyinfluencedby
the cultural, ethical and legal background of the region
[14].
EXAMPLES OF IMPORTANCE OF KNOWLEDGE

WORKERFROMMANUFACTURINGINDUSTRY
To demonstrate above theory I decided to give three
examples of importance of knowledge workers for
manufacturing industry. I did not use examples of
employees who are usually perceived as knowledge
workers like researches, designers, managers. I
deliberately give examples of people who may not be
classifiedasknowledgeworkersforthefirstsight.
Thecleaninglady
The organisation in the machinery industry had a very
specific production line, very sensitive to certain types of
chemicals. Therefore the hall where the production line
was located required to follow special rules for cleaning.
The organisation had a group of devoted cleaning ladies
who followed the rules rigidly, e.g. they knew which
chemicals to use and which were forbidden in this hall.
They worked so perfectly that organisation got use to it
and took it for granted. One of cleaners got ill and they
hirednewone.Duringherfirstshiftsheturnedouttobe
anexcellentcleaner,therealperfectionist.Everythingwas
shining, including the hall with that production line.
Unfortunatelytheforbiddenchemicalwasused.
Themaintenancemen
Johnwasalwaysbrilliantinmaintainingthathugemachine
in the middle of the assembly line. He just crawl close,
listentothesoundoftheengine,saidyes,repaireditand
that was all. John retired and the machine broke after
some time. The new maintenance men did exactly what
he saw John doing. Crawled close, listen to the sound of
theengine,saidyes,repaireditandnothing.Themachine
did not start. So he crawled close again, listen to the
sound of the engine again, said may be, and repaired it.
The same result, the machine did not start. He repeated
theprocessonceagainandthenthetechniquewascalled
to help him. Soon the machine looked like a seriously ill
patient in the hospital. Cables and testing devices
everywhere but the machine still refused to work. The
assemblylinestopfor48hours,costswereenormousand
thensuddenly,themachinestarted.Nobodyknewwhy.
BASICSONKNOWLEDGEWORK
Due to its tacit dimension, knowledge is of an intangible
character.Theintangiblecharacterofknowledgeleadsto
specifics of knowledge work. These specifics complicate
the management of knowledge work and knowledge
workers.Thespecificsofknowledgeworkaremostvisible
when knowledge work is compared to nonknowledge
work.
Tab. 2 Differences between knowledge and non
knowledgework
Characteristics
MajorRaw
Material
ProcessofWork
WorkVisibility
NonKnowledge
Work
KnowledgeWork
Materialelements
Knowledge
Obvious
Hidden
High
Low
Directand
Nondirect,effects
LinkstoResults
immediate
delayed
Concentratedin
Diffusedintheheadsof
Knowledge
thehandsof
employees
managers
Positionofthe
Profession,knowledge
employeeinformal
andpositionofthe
Powerbasedon
andpower
employeeinpower
structuresofthe
structuresofthe
organisation
organisation
Workis
Linear
Nonlinear
Waythe
Employeeevaluatesthe
employee
Basedonposition
situationanddecides
respondsto
andtask
thewaytorespondtoit
varioussituations
himself
Standardsare
Byothers
Employeehimself
developed
Controlis
Workandresultsof
Employee
directedto
work
Performanceis
Accordancewith
Employeecontribution
measuredby
standards
Roleofemployee
Tool
Agent
Howtomixthesubproduct
The organisation in the pharmaceutical industry used a
special sub product for one of the drugs they were
producing.Theyneededonlysmallamounteverydayand
thesubproductdidnotchangeintime,sotheyproduced
itonlyfromtimetotime.Todoso,theyhadtodisconnect
twopipesoftheirproductionline,puttheminthebucket
andmixchemicalstheycontained.Simplysaid,difficultto
do.Theproportionofdrugsinthesubproducthadtobe
exact,whichwasverydifficulttoachieve.Nobody,except
of one old worker could do it. It was natural that they
always called him to do this unpopular work. When he
broke the leg and was hospitalised no one paid it special
attention. Then they had to mix the sub product. It was
funatthebeginning,thedisasterlater.Finally,theyhadto
visittheircolleagueinthehospitaltotrytoexternalizehis
strangetacitknowledge.Whenhereturnedtowork,four
other people were chosen to get training. They met one
Saturday in the factory and they were mixing and mixing
tillwhattheproductoftheireffortwasacceptable.
Thetableshowsthatthedifferencesbetweenknowledge
andnonknowledgeworkisconsiderable.Knowledgeand
not the material element is the major raw material for
knowledgework.Asopposedtononknowledgework,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. It cannot be observed and
controlled, and it is not linear. Many knowledge workers
talkabouttheBBB(bed,bathorbus)syndrome.TheBBB
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 results of knowledge work may differ from the short
and long term perspective, which causes problems with
standards, measurement and evaluation. The growing
importanceofknowledgeworkchangespowerrelationsin
organisations. Managers used to be the people who had
more knowledge, more decision making rights and the
righttocontroltheirsubordinates.Whenknowledgework
is involved, power shifts from managers to subordinates.
They have more knowledge and they often understand
what they are doing much more than their managers.
Many of them make the final control of their product or
servicethemselves[14].
CONCLUSIONS
As examples show, knowledge workers are important
employees who directly influence performance of their
organisations, organisations in manufacturing industry
including. The trouble is that those most productive and
most important may be invisible till they leave their
organisation taking their knowledge with them.
17
L. Mldkov
[14] MLDKOV, L. (2012) Management of Knowledge

Workers,IuraEdition,SR,ISBN9788080784638.
[15] NOMIKOSG.E.(1989):ManagingKnowledgeWorkers
for Productivity. National Productivity Review, 8(2).
1989.
[16] NONAKA,I.,KONNO,N.(1998)TheconceptofBa:
Building foundation for Knowledge Creation.
CaliforniaManagementReviewVol40,No.3Spring
[17] NONAKA I., TOYAMA, R. KONNO, N. (2000) SECI, Ba
and Leadership: a Unified Model of Dynamic
Knowledge,LongRangePlanning,Volume33,Issue1,
1February2000,Pages534.
[18] NONAKA I., TAKEUCHI, H. (1995): The Knowledge
CreatingCompany:HowJapaneseCompaniesCreate
theDynamicsofInnovation.OxfordUniversityPress.
UK.1995.ISBN019509269.
[19] REICH, R.B.(1992):TheWorkofNations.NewYork:
VintageBooks.
[20] SVEIBY,K.E.(1997):TheNewOrganisationalWealth:
Managing and Measuring KnowledgeBased Assests.
1997.BerrettKoehler.
[21] TOBIN, D. (1996): Transformational Learning
Renewing Your Company Through Knowledge and
Skills.JohnWiley&Sons,NY.
[22] TOFFLER, A. (1990): Powershift: Knowledge, Wealth
and Violence at the Edge of the 21st Century. 1990.
BantamBooks.ISBN0553292153.
[23] TOMLINSON M. (1999): The Learning Economy and
Embodied Knowledge Flows. Centre for Research on
Innovation and Competition. Discussion paper 26.
UniversityofManchester.1999.
[24] TURBAN, E. (1992): Expert Systems and Applied
Artificial Intelligence, Maxwell Macmillan, New York,
1992.
[25] VAIL, E. F. (1999): Knowledge mapping: Getting
started with knowledge management. Inf. Syst.
Management.16(4),1999.p.1623.
[26] VEBER, Jaromr a kol. (2000): Management, zklady,
prosperita, globalizace. Management Press. Praha..
ISBN8072610295.
[27] VINSON,J.[accessed15.8.2009]<www.vinson.com.>
[28] WOLF,H.(1990):WebstersNewWorldDictionaryof
theAmericanLanguage.G.andC.Merriam.
[29] WIIG, K. (1993): Knowledge Management
Foundation.SchemaPress.
[30] YAU,J.W.(2003):DefiningKnowledgeWork:aBritish
and Hispanic CrossCultural Study. Department of
Computer Science. University of York. 2003. In
BRINKLEY, I., FAUTH, R., MAHDON, M.,
THEODOROPOULOU S.: Knowledge Workers and
KnowledgeWork.AKnowledgeEconomyProgramme
Report.
Knowledge of knowledge workers is often tacit, e.g.

difficult to share and express in explicit form. When
organisations loose knowledge workers, knowledge they
managetocaptureisoftenthefragmentofhisknowledge.
To minimise problems with knowledge workers and their
knowledge, organisations are advised to work with this
groupofemployeessystemicallyandtofindthewayhow
tomotivatethemtosharewhattheyknow.
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CAMARRILLO, P. M. (2006): Prototype System for
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[3] BAIR, J. H., OCONNOR, E. (1998): The state of the
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18

TheProceedings
Integrated AHP and TOPSIS Approach for Supplier Selection

BaharSennaroglu1Sedaen2
1
MarmaraUniversity,Istanbul,Turkey,Email:bsennar@marmara.edu.tr
INGBank,Istanbul,Turkey,Email:seda.sen@ingbank.com.tr
ARTICLEINFO:
Received:19September2012/Revised:24September2012/Accepted:2October2012
Abstract:
AHP
Supplierselection
TOPSIS
Thestudywasconductedforacompanywhichmanufactureslowvoltageswitchingdevices.Thecompany
purchasescapscrewsfromthedomesticmarketwhicharerawmaterialsfortheproductionofcontactors.
ThereisaneedtohavestrongrelationshipandintegrationwithitssuppliersforasuccessfulSupplyChain
Management(SCM)system.Therefore,theobjectiveofthisstudyistorankthefourdifferentsuppliersof
capscrewsandselectthemostsuitableoneasthemainsupplier.Firstly,thehierarchyofsupplierselection
criteriawasdeveloped.ThentheweightsofcriteriaweredeterminedusingtheAnalyticHierarchyProcess
(AHP).Finally,therankingandselectionprocesswascarriedoutbytheTechniqueforOrderofPreference
by Similarity to Ideal Solution (TOPSIS). The AHP weights were used in applying TOPSIS method. The
integrated AHP and TOPSIS approach employed for supplier selection problem can be applicable to any
otherselectionproblem.
Citation:SennarogluB,enS. IntegratedAHPandTOPSISApproachforSupplierSelection,2ndInternationalConferenceManufacturingEngineering&Management2012,(2012),p.19
22,ISBN9788055312163
INTRODUCTION
programming models 17%, Analytic Hierarchy Process
(AHP)15%,CBR11%,AnalyticNetworkProcess(ANP)5%,
fuzzy set theory 10%, simple multiattribute rating
technique (SMART) 3%, genetic algorithm (GA) 2%, and
criteria based decision making methods such as ELECTRE
and PROMETHEE 7%. Based on an extensive literature
survey Bruno et al. [5] conclude that AHPbased models
are useful in constructing structured and formalized
approaches for supplier evaluation and can be used in
combination with many other approaches. Based on a
literaturereviewof78journalarticlesfrom2000to2008
on MCDM approaches for supplier evaluation and
selection Ho et al. [6] conclude that the most prevalent
individual approach is DEA, whereas the most popular
integrated approach is AHPGP (Goal Programming); the
integratedAHPapproacheswithothertechniquesinclude
binegotiation,DEA,DEAandartificialneuralnetwork,GP,
grey relational analysis, mixed integer nonlinear
programming,multiobjectiveprogramming,andfuzzyset
theory.Theyalsoconcludethatthemostpopularcriterion
usedforevaluatingtheperformanceofsuppliersisquality,
followedbydelivery,price/cost,manufacturingcapability,
service, management, technology, research and
development, finance, flexibility, reputation, relationship,
risk, and safety and environment. Chen et al. [7] use the
fuzzyTOPSISmethodforsupplierselectionproblem.Chen
[2] uses DEA technique to screen potential suppliers and
thenTOPSISmethodtorankthecandidatesuppliers.This
study uses a methodology which combines AHP and
TOPSIS methods for a supplier selection problem. The
objective is to select the most suitable supplier among
fouralternativesforacompanymanufacturinglowvoltage
switching devices. The company purchases cap screws
fromthedomesticmarketwhicharerawmaterialsforthe
production of contactors. It needs to select its main
supplierforpurchasingcapscrewstoworkcollaboratively
initssupplychain.
Supply Chain Management (SCM) is a process of

organizing the activities from the customers order
throughfinaldeliveryforspeed,efficiency,andquality[1].
One of these activities is purchasing. SCM has an
increasing importance in todays competitive business
world and companies need to have strong relationships
andintegrationswiththeirsuppliersforasuccessfulSCM
system. Supplier selection problem is a multiple criteria
decision making (MCDM) problem typically having
conflicting criteria that include both qualitative and
quantitative measures. Due to strategic importance of
supplier selection process, extensive research has been
doneonsupplierselectioncriteriaandmethods.Chen[2]
summarizes important criteria for supplier selection from
the literature as price, delivery, quality, equipment and
capability, geographic location, technical capability,
management and organization, industrial reputation,
financial situation, historical performance, maintenance
service, service attitude, packing ability, production
control ability, training ability, procedure legality,
employment relations, communication system, mutual
negotiation, previous image, business relations, previous
sales, guarantee and compensation. De Boer et al. [3]
present a review of decision methods reported in the
literature for supporting the supplier selection process.
They define prequalification as the process of reducing
the set of all suppliers to a smaller set of acceptable
suppliers and present categorical methods, data
envelopment analysis (DEA), cluster analysis, and case
basedreasoning (CBR) systems as the decision methods
for prequalification of suitable suppliers. They present
linear weighting models, total cost of ownership models,
mathematical programming models, statistical models,
and artificial intelligencebased models as the decision
modelsformakingafinalchoiceamongsuitablesuppliers.
Agarwal et al. [4] review sixtyeight articles from 2000 to
2011tofindoutthemostprominentMCDMmethodology
followed by the researchers for supplier evaluation and
selection.TheyreportthedistributionofMCDMmethods
used in these articles by DEA 30%, mathematical
THEANALYTICHIERARCHYPROCESS(AHP)
AHP was developed by Thomas Saaty [8]. AHP
decomposes a complex MCDM problem into a system of
19
B. Senaroglu, S. en
The Technique for Order of Preference by Similarity to

IdealSolution(TOPSIS)
Yoon and Hwang [12] introduced the TOPSIS method
based on the idea that the best alternative should have
theshortestdistancefromthepositiveidealsolutionand
farthestdistancefromthenegativeidealsolution.TOPSIS
is a multiple criteria decision making (MCDM) method to
identify solutions from a finite set of alternatives. The
TOPSIS method evaluates the decision matrix X x
hierarchies [9]. Once the hierarchy has been structured,

the relative weights must be established for each factor
(alternatives, attributes, or criteria) on a given level with
respecttoeachfactoronthelevelimmediatelyaboveitby
usingpairwisecomparisons(Table1)amongthefactorson
thegivenlevel[10].
Tab.1Scaleusedforpairwisecomparisons
Value
(aij)
Definition
Explanation
iandjareequally
important
iisslightlymoreimportant
3
weakimportance
thanj
iisstronglymore
5
strongimportance
importantthanj
verystrong
iisverystronglymore
7
importance
importantthanj
extreme
iisabsolutelymore
9
importance
importantthanj
2,4,6,
usedwhenacompromise
intermediatevalues
8
isneeded
1
equalimportance
ij mxn
xij
rij
i 1, 2,..., m; j 1, 2,..., n
xij2
i 1
Thenormalizationisdoneforconvenienceofcomparison
byconvertingdifferentunitsofcriteriatoaunifiedunit.
Step2.Calculatetheweightednormalizeddecisionmatrix
V vij .Theweightednormalizedvalueiscalculated
mxn
as
vij ( w j )(rij )i 1, 2,..., m; j 1, 2,..., n
where w j istheweightofthejthcriterionand
w
j 1
Step 3. Determine the positive ideal solution (PIS) and

negativeidealsolution(NIS) A :
max v | j J , min v | j J , i 1, 2,..., m v , v ,..., v

A min v | j J , max v | j J , i 1, 2,..., m v , v ,..., v
A
ij
ij
ij
ij
where J is a set of benefit criteria and J is a set of cost

criteria.
Step 4. Calculate the separation measures, using the n
dimensionalEuclideandistance.
Theseparationofeachalternativefromthepositiveideal
solution:
aijajk=aik,foralli,j,andk
Theconsistencyratio(CR)isusedtotestconsistency:
Si
CI
RI
n n
CI max
n 1
1.98(n 2)
RI
n
CR
(v
j 1
v j ) 2 i 1, 2,..., m
ij
Theseparationofeachalternativefromthenegativeideal
solution:
Si
(v
j 1
ij
v j )2 i 1, 2,..., m
Step 5. Calculate the relative closeness to the ideal

solution:
where CI and RI are the consistency index and random

consistencyindexofA,respectively.Thevalueofnmaxis
calculatedfrom:
Ci
Si
i 1, 2,..., m;0 Ci 1
Si Si
Step 6. Rank the alternatives with respect to Ci in the

descending order. The preferred alternative should have
theshortestdistancefromthepositiveidealsolutionand
the farthest distance from the negative ideal solution,
whereahigher Ci wouldmeanhigherpreference.
, nmax n
If CR 0.1, the level of inconsistency in the comparison

matrix A is acceptable. Otherwise, the inconsistency is
high and the decision maker is advised to revise the
elementsaijofAtorealizeabetterconsistency.
Application of the integrated AHP and TOPSIS approach

forsupplierselection
The hierarchy of supplier selection criteria was
determined through interviews with the decision makers
20
mxn
the number of criteria. The normalized value rij is

calculatedas:
The procedure for the determination of the relative

weightsisasfollows[11]:
Assuming that there are n criteria at a given level of the
hierarchy, the procedure establishes an n n pairwise
comparisonmatrix,A.Lettingaijdefinetheelement(i,j)of
A,thepairwisecomparisonismadesuchthatthecriterion
in row i (i=1,2,,n) is ranked relative to every other
criterion in column j (j=1,2,,n) where all the diagonal
elements aii of A must equal 1. Consistency in judgment
requires that aij = k automatically implies that aji = 1/k.
The comparison matrix A is standardized by dividing the
elements of each column by the sum of the elements of
the same column. The sum of column elements of the
resulting normalized matrix N is equal to 1. The relative
weights are computed as the row average of matrix N. If
the decision maker exhibits perfect consistency in
specifying the entries of the comparison matrix A, the
columns of the normalized matrix N are identical.
Mathematically,acomparisonmatrixAisconsistentif:
Aw nmax w
ij
which refers to m alternatives which are evaluated in

termsofncriteriaanddenotestheperformancemeasure
oftheithalternativeintermsofthejthcriterion.Itssteps
areasfollows[9]:
Step 1. Calculate the normalized decision matrix
R r wheremisthenumberofalternativesandnis
B. Senaroglu, S. en
criteriaexistedwithrespecttoholdingstock,thenumber
of matrices was reduced from seven to six. The
inconsistency of each pairwise comparison matrix was
examinedbyCRexceptthe2x2matrix.Sincethecolumns
ofany2x2comparisonmatrixaredependent,a2x2matrix
isalwaysconsistent.Whenthelevelofinconsistencywas
found inacceptable, the elements of the related matrix
were revised with the decision makers. The composite
weights of criteria were found by multiplying each sub
criterionweightbyitsrelatedmaincriterionweight.Fig.3
presents the weights found using AHP method and
applicationstepsoftheTOPSISmethod.Thecomputations
werecarriedoutusingExcel2010.Thedecisionmatrixfor
theTOPSISmethodwasformedwiththedecisionmakers
evaluationsof4supplieralternatives(SupplierA,B,C,and
D)intermsof21subcriteriaunder7maincriteria.Asan
evaluation scale a 0100 scale was used where 100
represented the best value and 0 represented the worst
value for an alternative with respect to a criterion.
Therefore, all criteria were benefit criteria. According to
the preference rank order of the best alternative was
SupplierA,andthusitwasselectedasthemainsupplierof
the company for purchasing cap screws. The company
strategywastosetupstrongandlongtermrelationships
with one selected supplier to overcome quality, delivery,
andcostproblems.
inthecompany(Table2)andaccordinglythehierarchical
structure of the problem was developed (Figure 1). The
decisionproblemhas4alternativestobeevaluatedunder
7maincriteriaand21subcriteria.
Tab. 2 Hierarchy of supplier selection criteria for the
company
MainCriteria
Quality
Cost
DeliveryTimeand
Transportation
MinimumOrder
Quantity
Production
Capacity,
Technologyand
Flexibility
HoldingStock
PaymentTerm
SubCriteria
Qualityinspection
methods
Percentageofrefused
products
Highqualityemployee
Productperformance
Discountdependenton
purchasingquantity
Outsourcingcosts
Holdingcosts
Deliveryspeed
Justintimedelivery
Transportationcosts
Flexibilityondelivery
time
Holdingstockondesired
quantity
Suppliersadaptationto
requestedquantity
Utilizationofthecapacity
Productvarietythatcan
beproducedbythe
supplier
Operationamendment
tendency
Abletorespondto
changesofquantity
Specialstockholdingfor
thefirm,separately
Ontimepayment
Abidebypayment
conditions
Typeofpayment
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. 1 Hierarchical structure of the supplier selection

problem
The composite weights of criteria were determined using
AHP.Firstly,thepairwisecomparisonmatrix(a7x7matrix)
forthemaincriteriawaspreparedbytheconsensusofthe
decision makers of the company. In order to determine
the relative weights of the sub criteria within their main
criterion,sixpairwisecomparisonmatrices(4x4,3x3,4x4,
2x2, 4x4, and 3x3 matrices) were prepared by the
consensus of the decision makers. Since a single sub
Fig. 2 Computations for integrated AHP and TOPSIS

approach
21
B. Senaroglu, S. en
[4] Agarwal,P.;Sahai,M.;Mishra,V.;Bag,M.;SinghV.A
review of multicriteria decision making techniques
for supplier evaluation and selection. International
Journal of Industrial Engineering Computations, 2
(2011),pp.801810.
[5] Bruno,G.;Esposito,E.,Genovese,A.;Passaro,R.AHP
based approaches for supplier evaluation: Problems
and perspectives. Journal of Purchasing and Supply
Management,
(2012),
http://dx.doi.org/10.1016/j.pursup.2012.05.001.
[6] Ho, W.; Xu, X.; Dey, P. K. Multicriteria decision
making approaches for supplier evaluation and
selection: A literature review. European Journal of
OperationalResearch,202(2010),pp.1624.
[7] Chen, C.T.; Lin, C.T.; Huang, S.F. A fuzzy approach
for supplier evaluation and selection in supply chain
management. International Journal of Production
Economics,102(2006),pp.289301
[8] Saaty, T. L. The Analytic Hierarchy Process, McGraw
Hill,NewYork,1980.
[9] Triantaphyllou, E. MultiCriteria Decision Making
Methods: A Comparative Study, Kluwer Academic
Publishers,Dordrecht,2000.
[10] Shtub, A.; Bard, J. F.; Globerson, S. Project
Management: Engineering, Technology and
Implementation,PrenticeHall,NewJersey,1994.
[11] Taha,H.A.OperationsResearch:Anintroduction,8e,
PearsonPrenticeHall,NewJersey,2007.
[12] Yoon, K. P.; Hwang, C.L. Multiple Attribute Decision
Making: An Introduction, Sage Publications,
California,1995.
CONCLUSION
Managing the links between the suppliers and customers
successfully in a supply chain necessitates their active
collaboration. As a result, companies prefer to work
closelywithafewsuppliersordependableonesupplierin
order to achieve and maintain high supply chain
performance. Due to strategic importance of supplier
evaluation and selection process, extensive research is
being done to cope with this MCDM problem. This study
presentsanintegratedAHPandTOPSISapproachwithan
application to supplier selection decision problem of a
company. The integrated AHP and TOPSIS approach is
proposedasanefficientandeffectivemethodologytobe
used by decision makers on supply chains in terms of its
ability to deal with both qualitative and quantitative
performance measures. The proposed methodology can
also be applied to any other selection problem involving
multipleandconflictingcriteria.
REFERENCES
[1] Meredith, J. R.; Shafer, S. M. Operations
Management or MBAs, 3e, John Wiley, New Jersey,
2007.
[2] Chen, Y.J. Structured methodology for supplier
selection and evaluation in a supply chain.
InformationSciences,181(2011),pp.16511670.
[3] De Boer, L.; Labro, E.; Morlacchi, P. A Review of
Methods Supporting Supplier Selection. European
Journal of Purchasing and Supply Management, 7
(2001),pp.7589.
22

TheProceedings
Method to determine the analytical approximate description of nonsteady fluid film force in fluid film bearings
AlessandroRuggiero1SergejHloch2
1
DepartmentofIndustrialEngineering,UniversityofSalerno,Italy,Email:ruggiero@unisa.it
FacultyofManufacturingTechnologiesTUKEwithaseatinPreov,SlovakRepublic,Email:sergej.hloch@tuke.sk
ARTICLEINFO:
Category:PreliminaryCommunication
Received:21October2012/Revised:11November2012/Accepted:12November2012
Analyticalfluidfilmforce
Hydrodynamiclubrication
Journalbearing
Stiffnessanddampingcoefficients
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. The analysis has been
conducted assuming the Warner solution for the pressure field. The analytical approach to analysing the
behaviourofasystemismoreeffectivethananumericalinvestigationandmakesitpossibletocovernot
onlytheindividualcasebutalsothewholeclasstowhichthesysteminquestionbelongs.Furthermorethe
modelproposedallowusaquicklyanalyticaldeterminationofthestiffnessanddampingcoefficients.
Citation: RuggieroA,HlochS. Methodtodeterminetheanalyticalapproximatedescriptionofnonsteadyfluidfilmforceinfluidfilmbearings,2ndInternationalConference

ManufacturingEngineering&Management2012,(2012),p.2326,ISBN9788055312163
INTRODUCTION
The analytical approach to analysing the behaviour of a
system is more effective than a numerical investigation
andmakesitpossibletocovernotonlytheindividualcase
but also the whole class to which the system in question
belongs. The analysis of many aspects of the dynamic
behaviour of a rotor on lubricated bearings, such as the
time transient analysis, requires an analytical model in
ordertoprovidearapiddescriptionofthehydrodynamic
forcefieldgoverningtheinteractionbetweenjournaland
bearing. In fact, the use of pure numerical transient
analysis incurs the computational expense of solving the
twodimensional Reynolds equation with the numeric
methodsinordertodeterminethefluidfilmforceatevery
time step of the numerical integration procedure of the
motion equations. In the present paper a analytical
approximated fluid film force in finite journal bearing is
proposed. The analysis is basedon the description of the
pressure field in the gap using the Warners flow
correctionfactor[1].Thedescriptionoftheanalyticalfluid
filmforceproposedallowustheanalyticaldetermination
ofstiffnessanddampingcoefficientandtheanalysisofthe
stabilityofjournalsorbitforvaluesofimbalanceassigned
[3].
R 1 2 sin
cos
p L p ( ) p a 6
22
C
1
1
2
1 cos 1 cos
and:
z , 1
(2)
Coshzq
Coshq
(3)
arerespectivelytheSommerfeldsolutionforthecavitated
infinite long bearing [2] and Warners flow correction
factorwithqandindicatedinthefollowingrelations:
q2
dp
h 3 L d
d
p L 2 d
Whereiscalculatedfromequations[2]:
2 2 cos 1 2 sin 0
2 2 sin 1 2 cos 0
ANALYSIS
(4)
and pa thepressurefor 0 .
WithreferencetothejournalbearinginFigure1thepair
of coordinates , z identifies the generic point T on the
internalsurfaceofthebearingwhiletheintersectionpoint
P of the journal axis on the bearing middle plain is
identifiedbythepairofcoordinatese, [4].Thethickness
oftheoilfilm, whichisassumedtobeindependentfrom
theaxialcoordinate,is:
h C (1 cos )
assuming the film pressure distribution proposed by

Warner[1]:
(1)
pw , z p L z ,
where:
Fig.1Notationsforjournalbearing
Thedimensionlessforcecomponentsfreftareobtainedby
integratingthepressureoverthefilmdomain:
23
A. Ruggiero, S. Hloch
1
fr

f t 1
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 , , cos
S
2
1
3
M 2 6 f t , , sin
S
2
(6)
Fig.2Fulljournalbearing;criticalmassversusSommerfeld
number,forvariousaspectratiosL/D(Constantinescumap
[2])
Wherewith
S
2
RL R ,
M , p p , M SW ,
M
0
W C
p0
2C
M0
R
p0 6
C
InFigures3,4,5,6,7and8areshowntheorbitofthecentre
of the journal, for fixed operating condition indicated in
Figure 2, using the Warners flow correction factor. The
orbit have been obtained integrating the differential
equations(6)withaMathematica4.0biltinfunction.
(7)
are identified the Sommerfeld number, dimensionless

mass, dimensionless pressure, reference mass and
reference pressure. The dimensionless fluid film force
componentsfrandftcanbewriteinfollowingform:
1 2
I 6 I 3 I 5 I 2 , ,;
f r
22
1 2
I 4 I1 I 6 I 3 , ,;
ft
22
STIFFNESS
AND
CALCULATION
(8)
tanh q
)
q
(9)
C xx
I4
sin 2
d ;
I2
sin 2
d ;
h
I5
h2
cos 2
d ;
I3
cos 2
d ;
h
I6
h2
sin cos
h2
sin cos
d
h
(10)
f r 0
Substitutingthe(10)and(9)in(8)weobtaintheanalytical
expression of fluid film force components fr and ft in
explicit form (see Appendix). On the other hand we can
obtainthedimensionlessforcecomponentsfxandfywhit
simpletransformation:
f x sin

f y cos
cos f r

sin f t
f r
f
2 2
, r
2 2 4
f t 0
(11)
f t
xy xy
f x
;
y 0
C yx
f y
x 0
4 2
22 4
4 ( 2 4 ) , f r
( 2 2 4 ) 2
(1 2 )3 / 2
(2 ) 1 2
(12)
x2 y2
Mx f x x, y, x, y
1
My f y x, y, x, y
S
(2 2 2 4 )
(4 3 4 6 ) 1 2
f t
1 2
f t
weobtainthedifferentialequationofmotioninreference
fixedframe:
(13)
24
C xy
x2 y2
f y
;
y 0
2
2
2
; Tan x ; x y ;
xx yy
C yy
andsetting:
oxy
f x
;
x 0
where the subscript "0" denotes that they have to be

evaluate at an equilibrium position. The analytical
determinationofthestationaryderivativeofthefluidfilm
force components fr , ft (the infinitely long bearing
modelcomponents)andqwillmakepossiblewith(2.7)to
get the analytical expression of stiffness and damping
coefficients.
were:
I1
f y
f y
f x
f
; K yy
; K xy x ; 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. Stiffness
and damping coefficients are required for both
synchronous response calculations and linear stability
analysisandtheyaredeterminedasfollows:
with:
, , ; dz 2(1
DAMPING
2
(2 ) 1 2
2
8 4 2 6 4 3 6 4(2 2 2 4 ) 1 2
(1 ) 2 2 ( 2 3 2 1 )
2
2 2
2 (2 2 )
( 2 3 2 2 1 2 ) 1 2
And
0.75
0.5
0
0.25
Assumingasparameterofstabilitymasdonebyothers
authors:
-1
CM 2
m
W
02
0.25
0.5
0.75
-0.25
bysetting:
-0.75 -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.5 Orbit of the journal for approximate finite model

journalbearingwith:M=8.75,S=0.63,L/D=1
C xxC yy C xy C yx
thevalueofmatthresholdofinstabilityis:
(PointCConstantinescumap)
1
m0 20
0
0.75
1
0.5
0.75
0.25
0.5
-1
-0.75 -0.5 -0.25
0.25
0.5
0.75
0.25
-0.25
-1
-0.75 -0.5 -0.25
0.25
0.5
0.75
-0.5
-0.25
-0.75
-0.5
-1

-0.75
-1

journalbearingwith:M=1.75,S=3.14,L/D=0.5
(PointDConstantinescumap)
1
(PointAConstantinescumap)
0.75
0.5
0.75
0.25
0.5
-1
-0.75 -0.5 -0.25
0.25
0.5
0.75
0.25
-0.25
-1
-0.75 -0.5 -0.25
0.25
0.5
0.75
-0.5
-0.25
-0.75
-0.5
-1

-0.75
-1

journalbearingwith:M=2.55,S=3.14,L/D=0.5
(PointEConstantinescumap)
(PointBConstantinescumap)
25
1
0.75
h h /C
L
0.5
0.25
-1
-0.75 -0.5 -0.25
0.25
0.5
0.75
p0 6R / C 2
p p / p0
R=
-0.25
S RL
-0.5
R C
2
-0.75

-1
e/C
=L/D
(PointFConstantinescumap)
CONCLUSIONS
m M 2C /( SW )
With reference to finite length plain journal bearings, in

theassumptionsoflaminar,incompressibleandisoviscous
flowmadeinadditiontothenegligibilityoffluidinertiaso
astojustifytheuseofthestandardformoftheReynolds
equation, assuming the Warners flow factor correction
for the pressure field, has been determined the
approximate analytical fluid film force field. The use of
proposedmethodisrecommendedinalltypesofbearing
analysisthatfavourananalyticalapproach,i.e.inallcases
inwhichtheaimistoobtain abettertradeoffbetween
accuracy and computational expense. The present paper
represents a method appliedto a finite journal bearing
modellingand,assuch,islikelytobeenhancedtotaketo
accountotheraspectonlubricationmechanismand/oron
thebearinggeometry.
x, y
x x ;y y
C
C
Fr,Ft
fr,ft
Load
Dynamicviscosity
Eccentricity
Eccentricityratio
Attitudeangle
Aspectratio
Journal mass (half of rotor
mass)
Dimensionlessjournalmass
Coordinatesofjournalcentrein
fixedsystemframe
Dimensionlesscoordinatesof
journalcentre
REFERENCE
[1] P. C. Warner: Static and dynamic properties of
partial journal bearings, Journal of Basic
Engineering,TransoftheASME,June1963.
[2] Constantinescu V.N., "Sliding Bearings", Allerton
Press,1985.
[3] V.D'Agostino, D.Guida, A.Ruggiero: " Sulla
Determinazione Analitica Dei Coefficienti Di
RigidezzaeSmorzamentoNeiCuscinettiLubrificati",
XIIICongressoNazionaleAIMETA,VolumeII,pp135
140.
[4] CaponeG.,D'AgostinoV.,GuidaD.,"AFiniteLenght
Plain Journal Bearing Theory", ASME Journal of
Tribology,Vol.116,648653,(1994).
Radialclearance
Bearingdiameter
Eccentricity
Components of the fluid film
forceinrotatingsystemframe
Dimensionless components of
26
Dimensionlesspressure
Bearingradius
Sommerfeldnumber
NOMENCLATURE
C
D=2R
e
the fluid film force in rotating

systemframe
Oil filmthickness
Dimensionlessoilfilmthickness
Bearinglength
Pressure
Referencepressure

TheProceedings
Green Supply Chain Management: A Case Study from Indian Small

and Medium Scale Industry
SanjeevKumar1SomnathChattopadhyaya2VinaySharma3
1
Mech.Engg.Department,IndianSchoolofMines,Dhanbad,India,Email:Sanjeevkg9@gmail.com
ME&MMEDepartment,IndianSchoolofMines,Dhanbad,India,Email:somuismu@gmail.com,
ProductionEngg.Department,BirlaInstituteofTechnology,Mesra,Ranchi,India,Email:vinay1970@gmail.com
2
3
ARTICLEINFO:
Received:20September2012/Revised:21October2012/Accepted:11November2012
Abstract:
IndianSmallandMediumScaleIndustry
SustainableSupplyChain
EnvironmentalPerformance
SteelIndustries
CaseStudy
Thisstudyaimstoinvestigatethesustainablesupplychainmanagementpracticeslikelytobeadoptedby
the manufacturing industry of steel in India. The approach of the present research includes a literature
review,indepthinterviewsandquestionnairesurveys.Therelationshipbetweensustainablesupplychain
managementpracticesandenvironmentalperformanceisstudied.Theresultsindicatethatperformanceof
steel industry regarding eco procurement, eco accounting, eco logistic design, eco product design, eco
manufacturing practices, marketing & communication, economic performance, environmental
performance, operational performance, customer cooperation, internal environmental management
performance, stakeholders vendor management etc. in response to the current wave of national &
internationalgreenissuesandalsoenvironmentalperformanceoftherespectiveindustries.
Citation: Kumar,S.,Chattopadhyaya,S.,Sharma,V.,Hloch,S., :GreenSupplyChainManagement:ACaseStudyfromIndianSmallandMediumScaleIndustry,2ndInternational

ConferenceManufacturingEngineering&Management2012,(2012),p.2732,ISBN9788055312163
INTRODUCTION
(2009)[9]havedevelopedamethodologytoidentifythose
customers, who are ready for paying more for green
products. Yuang and KielkiewiczYuang (2001) [11]
presented an overview of current practices in managing
sustainability issues in supply networks. Cross functional
teams consisting personnel from sales, environment,
purchaseandpersonnelfromotherrelevantdepartments,
canbefoundinorganizationswiththeadvancedstrategies
for
sharing
sustainabilityoriented
information.
Organizations provide to their consumers/ suppliers their
sustainability procurement policy, goals and future
targets.Organizationshavespecificcriteriaandrecognized
standards (ISO14001), technical (leadfree soldering) and
performancespecificationsthatitssuppliersmustmeetto
be recognized as preferred suppliers. Supplier
performances can be enhanced through onsite third
party auditing or periodic selfassessment by suppliers.
Training is administered to companies that provide not
onlyadviceonsustainabilityissuesinpurchasing,butalso
to deliver to suppliers to provide them with information
onproductlifecyclethroughcollaborationwithsuppliers.
Nagel (2000) [5] developed the tool to evaluate the
supplier's environmental performance based on lifecycle
analysis.Twodifferentapproaches;oneshowingabsolute
supplier performances in environmental perspective, the
other describing a relative supplier performance in a
business perspective were given. Gil et al. (2001) [1]
indicated that GSCM has a positive relationship with an
organization's economic performance. Brink et al., (1998)
[7] devised a system called ECOQUEST. The system
provides a questionnaire for suppliers to selfaudit their
environmental performance and gives them some
solutions to improve the environmental profile of their
product.Thesystemfunctionalityislimitedsinceitfocuses
on suppliers in the electronics industry and the
comparison of different suppliers performances is not
assessed. Deans, (1999) [4] indicated that an
environmentalinitiativeisongoingprocesswithintheUS
utilities industry which ensures that environmental
Environmental issues have become very important in

present times due to their high level of visibility.
Organizational management is forced to incorporate
environmental management into corporate practices
(ChenLungYangetal.2010)[3].Naturechangeswiththe
time. There is need to cope with the changes in the
managementsystemforitssurvivalandsustainabilitywith
respect to time (V.R.Pramod and D.K.Rawat, 2010) [8].
Environmental pollution is the main problem which may
lead to the extinction of mankind on earth if not
addressed in time. Regulations and legislation related to
environmentandthegreenbrandingdrivehastriggered
theadaptationandpracticeofgreentechniquesinsupply
chain management (Sikhar Barari et al. 2012) [6].The
concept covers all the phases of a products life cycle,
from the extraction of raw materials through the design,
production and distribution phases to the use of the
productbyconsumersandtheireventualdisposalofsame
(Bearing point, 2008) [2]. The number of organizations
ruminatingtheintegrationofenvironmentalpracticesinto
their strategic plans and daily operations is continuously
increasing. With global warming being recognised as one
ofthebiggestchallengesofthiscentury,carbonemissions
are increasingly becoming the centre of attention. Global
warming is the result of increasing CO2 (carbon dioxide)
concentrationintheatmosphere.Thestudyoftheimpact
ofsupplychainsontheenvironmentisrelativelynewand
arapidlygrowingresearcharea.Thegreenorsustainable
supply chain is an approach with attempts to minimize a
product or services ecological footprint (Bearing point,
2008)[2].
LITERATUREREVIEW
Thereareonlyafewstudiesrelatedtosustainablesupply
chain management. Approaches towards Sustainable
Supply Chain Management (SSCM) practice have been
identified by various researches; they are briefly outlined
below. Considering the consumers behavior for green
products as an important business issue, Wang et al.
27
S.Kumar et al.
Green Supply Chain Management: A Case Study from Indian Small and Medium Scale Industry
considerationsareasignificantfactorinpurchasingpolicy
andintheselectionprocessforsuppliers.Weietal.(1997)
[10] discuss about the neural network for the supplier
selection. Neural networks save a lot of time and money
for system development when compared to conventional
modelsfordecisionsupportsystem.Thesupplierselecting
system is based on two functions: one is the function
measuring and evaluating performance of purchasing
(quality,quantity,timing,price,andcosts)andstoringthe
evaluationinadatabasetoprovidedatasourcestoneural
network. The other is the function using the neural
network to select suppliers. This method incorporates
qualitativeandquantitativecriteria.Theweaknessofthis
method is that it demands software and requires a
qualifiedpersonnelexpertonthissubject.
convention,ifthepvalueislessthan0.05,itisconcluded
thatthenullhypothesiscanberejected).
Tab.1 Performance of Eco Procurement [Factor 1]
(AverageMeanscore:1.566)
DIMENSION
Providesdesignspecificationto
suppliersthatinclude
environmentalrequirementsfor
purchaseditem
Cooperationwithsuppliersfor
environmentalpurchasing
Existenceofcellfor
environmentalauditforsuppliers
internalmanagement
Procurementsmainlyfrom
ISO14000certifiedsuppliers
Secondtiersuppliers
environmentallyfriendlypractice
evaluation
Implementationofeco
labeling/ecologoofproducts
Workwithotherbusiness
functionstodiscussandimprove
purchasingprocedures.
Provisionofeducation/assistance
tosuppliersonenvironmental
mattersinordertoincrease
supplychainefficiency.
Communicationregarding
environmentalprocurement
criteria/requirementsto
marketingstaff,employees,
stakeholders,andcustomers
Cooperationwithcustomersfor
environmentalpackaging
OBJECTIVEOFTHESTUDY
Investigate the practice and implementation of
sustainablesupplychainmanagementinIndianSmalland
MediumScaleSteelmanufacturingindustries.
RESEARCHMETHODOLOGY
It has been observed that the contribution of steel
industries in India and around the world is large in the
growthofindustrialeconomy.TheCompetitiveStrategies
andBestPracticesBenchmarkingQuestionnairehavebeen
developed. Based on review of studies, finally researcher
hadarrivedatsetof105dimensionsaftereliminatingthe
redundant
dimensions
by
submitting
the
statements/dimensions to respondents and discussing
withexperts,whowerebelievedtohaveknowledgeofthe
subject for fair judgment. The questionnaire consists of
total14factorswith105underlyingdimensions.Industries
performance strategies will depend upon their aggregate
score. The model aims to explore possible near future
developments in the competitive strategies of the
companies by addressing their competitive priorities,
manufacturing objectives and action plans. The target
respondentsofsurveywererequestedtoindicate,usinga
fivepoint Likert scale (1 Below average/Completely
disagree,2Average/Rarelyagree,3Good/Partlyagree,4
Verygood/Ratheragree,5Excellent/Completelyagree),
the extent to which they perceived their industries
implementing each of the dimensions of Sustainable
Supply Chain Management practices. Dimension analysis
wasconductedforeachofthe105statements/dimensions
throughameanscore,ttestandptest.
1.56(0.527)
8.854
0.000
2.000(0.500) 12.000 0.000

1.555(0.527) 8.854
0.000
1.444(0.527) 8.222
0.000
1.222(0.440) 8.315
0.000
1.666(0.707) 7.071
0.000
1.444(0.527) 8.222
0.000
1.444(0.527) 8.222
0.000
1.444(0.726) 5.965
0.000
1.888(0.927) 6.107
0.000
EcoProcurement,whichhas10underlyingdimension.In
industry the most important dimension is Cooperation
with suppliers for environmental purchasing (2.000) and
the least important dimension is Secondtier suppliers
environmentally
friendly
practice
evaluation
(1.222).
Tab.2PerformanceofEcoAccounting[Factor2](Average
Meanscore:1.355)
COMPARATIVEANALYSISOFFACTOR,RESULTS
ANDDISCUSSION
DIMENSION
MEAN
(STD.DEV.)
Environmentalcostsassociated
withoperationsandprocesses
(e.g.monitoringandabatement 1.555(0.726)
equipment,wastedisposaletc.)
aretakencare
Accountingthecoststothe
customersassociatedwiththe
1.222(0.440)
useanddisposaloftheproducts
Communicationofenvironmental
coststocustomersandwithinthe 1.222(0.440)
industryinkeybusinessfunctions
Assistinginevaluationof
environmentalcostwithrespect
1.333(0.500)
tocapitalpurchasesandnew
technology
Generateactivitybasedcostingin
variousdepartmentorbusiness 1.444(0.726)
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
steelindustries.Asdiscussedearlier,14sustainablesupply
chain factors with 105 underlying dimensions considered
in this study and each dimension has its own importance
foreffectivesustainablesupplychainperformance.Asper
theliteraturereview&expertsview,usedlinkertscalein
thisquestionnaire,where1employsbelowaverage&5
employs excellent. Each scale signifies how these factors
for an industry for effective sustainable supply chain
factors. For these scores have been calculated the
competitive mean score witht and p value. Consider
null(0)hypothesisthatnosignificantdifferencesofgreen
supply chain factors. An alternate hypothesis there is
significantdifferencesofsustainablesupplychainfactors.
Herepistheprobabilityofacceptance(Thepvalueisa
numerical measure of the statistical significance of a
hypothesis test. It tells how likely it is that sample data
have responded even if the null hypothesis is true. By
6.424
0.000
8.315
0.000
8.315
0.000
8.000
0.000
5.965
0.000
Eco Accounting, which has 5 underlying dimension. In

industry the most important dimension is Environmental
costs associated with operations and processes (e.g.
monitoring and abatement equipment, waste disposal
28
MEAN
(STD.DEV.)
1.444(0.527) 8.222
0.000
1.222(0.440) 8.315
0.000
1.222(0.666) 5.500
0.001
remanufacturing(1.777).EcoManufacturing,whichhas
15 underlying dimension. In industry the most important
dimension is minimizing toxic/hazardous waste during
manufacturing(2.444)andtheleastimportantdimension
is Inclusion of recycling program for manufacturing
operation (1.222). Marketing and Communication,
which has 5 underlying dimension. In industry the most
important dimension is assisting customers to improve
their environmental performance (1.666) and the least
important dimension is Environmental requirement and
activities of customer concern are monitored (1.444).
Economic Performance, which has 5 underlying
dimension. In industry the most important dimension is
Reduction in cost of energy consumption (2.666) and the
least important dimension is Waste discharge
methodologyforreducingcost(2.000).
1.222(0.440) 8.315
0.000
Tab.5 Performance of Eco Manufacturing [Factor 5]

3.000(0.500) 18.00
0.000
etc.) are taken care (1.555) and the least important

dimension is Accounting the costs to the customers
associated with the use and disposal of the products
(1.222).
Tab.3 Pperformance of Eco Logistics Design [Factor 3]
DIMENSION
Reverselogisticsappliedin
stockplanning
Applicationofenvironmental
issuesinthedesignoflogistics
management
Identification,Collection&
distributionofproducts/parts
thatwillberecycled,reused
Recollectionplanningfor
packagingmaterial
Minimizingtheuseofpackaging
considered
MEAN
(STD.DEV.)
DIMENSION
Possibilityofproductbeing
recyclable,reusable
Avoidorminimizetheamount
ofhazardousmaterialusedin
productproduction
Aredesignersusinglifecycle
engineeringtoimprovethe
environmentalperformance
andproductionefficiencyof
theproducts
Measurestakentoreduce
material,water&energyused
inmanufacturing
Optimizingtheuseofenergy
generatedfromrenewable
sourcesinmanufacturing
operations
Inclusionofrecyclingprogram
formanufacturingoperation
Industryhasestablished
programtoincreasetheservice
intensityoftheproducts
Determinationof
environmentalimpactsand
costsoftheproducts
throughouttheirlifecycle
Minimizingtoxic/hazardous
wasteduringmanufacturing
Optimumenergyconsumption
duringmanufacturingprocess
Integratedenvironmental&
efficiencycriteria
implementationinprocess
design
Minimizinguseofnatural
resourcesduring
manufacturingisconsidered
Considerationof
environmentalissueinthe
processofproductionplanning
andcontrol
Environmentalissue
consideredduringselectionof
manufacturingprocess
EcoLogisticsDesign,whichhas5underlyingdimension.
In industry the most important dimension is minimizing
the use of packaging considered (3.000) and the least
important dimension is Application of environmental
issuesinthedesignoflogisticsmanagement(1.222).
Tab.4 Performance of Eco Product Design [Factor 4]
DIMENSION
Designofproductsfor
optimumconsumptionof
material/energy
Productdesignedforreuse,
recycle,recoveryofmaterial,
componentsparts
Designconsiderationof
productstoavoidorreduce
useofhazardousofproducts
Designofproductstoreduce
waste&costs
Productsaredesign&develop
meetenvironmental
regulationandsafety
standards
Cooperation&feedbackwith
customerindevelopingeco
design
Productsaredesign&
developedforeasein
dismantling&
remanufacturing
Applicationofvalue
engineering/analysisinthe
designofproducts
Evaluationofproduct
durability
Possibilityofeliminating
secondaryprocesses
(polishing/paintingetc.)
considered.
MEAN
(STD.DEV.)
2.111
(0.600)
1.888
(0.333)
10.539 0.000
17.000 0.000
2.000
(0.500)
12.000 0.000
1.888
(0.333)
17.000 0.000
2.000
(0.500)
12.000 0.000
2.111
(0.333)
19.000 0.000
1.777
(0.440)
12.095 0.000
1.777
(0.833)
6.400
2.111
(0.600)
10.539 0.000
1.777
(0.833)
6.400
0.000
0.000
EcoProductDesign,whichhas10underlyingdimension.
In industry the most important dimension is Design of
products for optimum consumption of material/energy
(2.111)andtheleastimportantdimensionisProductsare
design & developed for ease in dismantling &
Reducedsetuptime
29
S.Kumar et al.
MEAN
(STD.DEV.)
1.888
(0.600)
9.430
0.000
2.111
(0.333)
19.000
0.000
1.555
(0.527)
8.854
0.000
2.000
(0.500)
12.000
0.000
1.777
(0.440)
12.095
0.000
1.222
(0.440)
8.315
0.000
1.222
(0.440)
8.315
0.000
1.222
(0.440)
8.315
0.000
13.914
0.000
15.119
0.000
1.444
(0.527)
8.222
0.000
2.111
(0.600)
10.539
0.000
1.444
(0.726)
5.965
0.000
1.666
(0.866)
5.774
0.000
2.222
(0.971)
6.860
0.000
2.444
(0.527)
2.222
(0.440)
S.Kumar et al.
Tab.9 Performance of Customer Cooperation [Factor 9]

Tab.6 Performance of Marketing and Communication

[Factor6](AverageMeanscore:1.488)
MEAN
t
(STD.DEV.)
Assistingcustomerstoimprove
1.666
7.071
theirenvironmentalperformance (0.707)
Environmentalrequirementand
1.444
8.222
activitiesofcustomerconcernare
(0.527)
monitored
Awarenessregarding
1.444
environmentalinformationto
5.965
(0.726)
newandexistingemployees
Departmentalinteractionand
exchangeofinformation
1.444
5.965
regardingenvironment,
(0.726)
performance,efficiencyetc.
Useofenvironmental
informationduringproduct
1.444
8.222
marketing&communications
(0.527)
material
DIMENSION
DIMENSION
Cooperationfromcustomers
forecodesign
forcleanerproduction
forgreenpackaging
forusinglessenergyduring
producttransportation
Cooperationwithcustomers
forenvironmental
procurement
0.000
0.000
0.000
0.000
0.000
Tab.7 Performance of Economic Performance [Factor 7]

Wastedischargemethodology
forreducingcost
Reductionincostformaterials
purchasingwithoutaffecting
thequalityoftheproduct
Reductionincostofenergy
consumption
Effectivewastetreatment
managementforreducingcost
Reductionofthefinefor
environmentalaccidents
2.666
(0.500)
2.222
(0.440)
2.000
(0.707)
16.000 0.000
15.119 0.000
0.000
Minimizationofairemission
Minimizationofsolidwaste
Improveproduction
procedure/methodforreducing
waste/scrap
Recoverythroughsaleofscrap
andused/rejectedmaterial
Recoverythroughsaleofexcess
capitalequipment
Recoverythroughsaleof
old/obsoleteequipment
Recyclingofwastewater
Optimizationofmanpower
resourcesinproductionprocess
Reductionofconsumptionfor
hazardousmaterials
Reductioninfrequencyof
environmentalaccidents
MEAN
t
p
(STD.DEV.)
2.222
10.000 0.000
(0.666)
2.555
14.546 0.000
(0.527)
2.222
(0.440)
1.777
(0.666)
1.333
(0.500)
1.222
(0.440)
1.444
(0.726)
2.666
(0.500)
2.000
(0.866)
1.555
(0.527)
15.119 0.000
8.000 0.000
8.000 0.000
8.315 0.000
5.965 0.000
16.000 0.000
6.928 0.000
8.854 0.000
Environmental Performance, which has 10 underlying

Optimization of man power resources in production
process (2.666) and the least important dimension is
Recoverythroughsaleofold/obsoleteequipment(1.222).
30
2.666(0.500) 16.000 0.000

2.333(0.500) 14.000 0.000
2.444(0.726) 10.094 0.000
2.111(0.600) 10.539 0.000
p
0.000
0.000
0.000
0.000
0.000
Human and Technological Resources, which has 5

underlying dimension. In industry the most important
dimension is Improvement in worker safety (2.777) and
the least important dimension is Consultation with
environmental experts before using new technology
(1.222).Internal
Environmental
Management
Performance, which has 10 underlying dimension. In
industry the most important dimension is Promotion of
qualitycircles(2.111)andtheleastimportantdimensionis
Existence of policy related to green supply chain
management linking environmental, economic, process
performances (1.222). Operational Performance, which
has 10 underlying dimension. In industry the most
important dimension is Amount of goods delivered on
time (3.000) and the least important dimension is
Development of a prevention program to identify and
eliminate sources of pollution (1.333). Stakeholders,
which has 5 underlying dimension. In industry the most
important dimension is Consideration & application of
environmental issues because of trade organizations
(1.555) and the least important dimension is
Consideration & application of environmental issues
because of regulatory concerns (1.333). Vendor
Management, which has 5 underlying dimension. In
industry the most important dimension is Environmental
awareness among the vendors (1.555) and the least
importantdimensionisEnvironmentalissuesareregularly
sharedbyvendors(1.333).
Tab.8PerformanceofEnvironmentalPerformance[Factor
8](AverageMeanscore:1.900)
DIMENSION
2.555(0.527) 14.546 0.000
MEAN
t
(STD.DEV.)
Improvementinworkersafety 2.777(0.440) 18.898
Motivate
workers
for
2.000(0.500) 12.000
environmentalconsciousness
Increasesupervisortraining 1.444(0.527) 8.222
Use
of
energy
efficient
2.222(0.666) 10.000
technologies
Consultation with environmental
experts before using new 1.222(0.440) 8.315
technology
DIMENSION
10.000 0.000
8.485
Tab.10 Performance of Customer Cooperation [Factor 9]

MEAN
t
p
(STD.DEV.)
2.000
12.000 0.000
(0.500)
2.222
(0.666)
Customer Cooperation, which has 5 underlying

Cooperation from customers for cleaner production
(2.666)andtheleastimportantdimensionisCooperation
withcustomersforenvironmentalprocurement(2.111).
DIMENSION
MEAN
(STD.DEV.)
ofsuppliers
Consideration& applicationof
1.555(0.726)
environmentalissuesbecause
6.424
oftradeorganizations
Consideration&applicationof
1.444(0.527)
8.222
ofemployeeconcerns
Consideration& applicationof
1.444(0.527)
8.222
environmentalissuebecause
ofcustomer&marketpressure
Tab.11 Performance of Internal Environmental

Management Performance [Factor 11] (Average Mean
score:1.500)
MEAN
DIMENSION
(STD.DEV.)
Promotionofqualitycircles
2.111
(0.600)
Existanceofenvironmentaland
1.555
auditingprogram
(0.527)
Provisionoftrainingin
1.666
environmentalmanagement
(0.707)
ImplementationofISO14001
1.666
certification
(0.866)
Commitmentofgreensupplychain
1.333
managementpolicybysenior
(0.500)
managers
Awarenessaboutthegreensupply
1.333
chainmanagementmeasures
(0.500)
adoptedbythecompetitors
Existanceoftotalquality
1.444
environmentalmanagement
(0.726)
Updatingthecurrentandproposed
environmentalregulationsand
1.333
legislationthatmayimpacton
(0.500)
business
Existenceofpolicyrelatedtogreen
1.222
supplychainmanagementlinking
(0.440)
environmental,economic,process
performances
Supportforgreensupplychain
1.333
managementfromjunior&middle (0.500)
levelmanagers/executive
10.539 0.000
8.854 0.000
Reducedinventorylevel
Reductioninscrap
Promoteenvironmentalquality
products
Optimizationofcapacity
utilization
Amountofgoodsdeliveredon
time
Monitoringtheenvironmental
andimplementationforthe
improvementwithinindustry
Programtopromoteandtrack
thereductionofwaste
Wastemanagementprogramfor
compliancewithallapplicable
regulations
Selectionanduseofenergy
efficientequipmentsandfixture
forelectrical,mechanicaland
lightingapplication
Developmentofaprevention
programtoidentifyand
eliminatesourcesofpollution
Tab.14 Performance of Vendor Management [Factor 14]

DIMENSION
8.000 0.000
Environmentalperformanceisan
importantcriteriainvendor
selection
Environmentalawarenessamong
thevendors
Environmentalcertifiedvendoris
considered
Environmentalissuesare
regularlysharedbyvendors.
Feedbackonenvironmental
issuesfortheproductsupplied.
8.000 0.000
5.965 0.000
8.000 0.000
8.315 0.000
1.444(0.527)
8.222
0.000
1.555(0.726) 6.424
0.000
1.444(0.527) 8.222
0.000
1.333(0.500) 8.000
0.000
1.444(0.527) 8.222
0.000
RESULTANDDISCUSSION
While analyzing the sustainable supply chain factors in
steelindustryithasbeenobservedthat(figure1)themost
important factor is customer cooperation (2.422)
followedbyEconomicPerformance(2.222)andtheleast
important factor perceive is s Eco Accounting (1.355)
followed by Stakeholders (1.444), Vendor
Management (1.444). Therefore for the management
point of view they should give more strength on Eco
Accounting,stakeholders,EcoProcurement,Vendor
ManagementMarketingandcommunicationInternal
Environmental Management Performance for improving
sustainablesupplychainfactors.
14.546
0.000
13.914
0.000
12.095
0.000
26.000
0.000
5.987
0.000
1.444
(0.527)
8.222
0.000
1.444
(0.527)
8.222
0.000
1.444
(0.726)
5.965
0.000
2.000
(0.866)
6.928
0.000
1.333
(0.500)
8.000
0.000
Fig.1 Comparative analysis of effectiveness of sustainable

supplychainfactors
Itisalsoobservedthatinall105dimensionsofsustainable
supply chain factors, the value oft is more than 2. It
meansthatnullhypothesisofthesedimensionsisrejected
therefore it can be generalize that there is a significant
differences of sustainable supply chain dimension among
theindustry.Alsoitveryimportantthatthemanagement
oftheindustryshouldgivespecialfocusontheleastmean
scored dimensions in their organization, so that industry
leadstoprovidecustomersatisfactionthroughsustainable
supplychainperformance.
Tab.13PerformanceofStakeholders[Factor13](Average
Meanscore:1.444)
t
Consideration&applicationof
1.333(0.500)
8.000
ofregulatoryconcerns
Consideration&applicationof 1.444(0.527)
8.222
p
0.000
0.000
31
MEAN
(STD.DEV.)
8.000 0.000
MEAN
(STD.DEV.)
0.000
5.774 0.000
DIMENSION
0.000
Tab.12 Performance of Operational Performance [Factor

12](AverageMeanscore:2.033)
MEAN
(STD.DEV.)
2.555
(0.527)
2.444
(0.527)
1.777
(0.440)
2.888
(0.333)
3.000
(0.500)
0.000
7.071 0.000
DIMENSION
S.Kumar et al.
S.Kumar et al.
[4] I. Deans, 1999.An approach to the environmental

managementofpurchasingintheutilitiessector,Eco
Manage.Audit.Vol.6,No.1,pp.1117.
[5] Nagel, M. H., 2000. Environmental supply chain
managementversusgreenprocurementinthescope
of a business and leadership perspective.
International Symposium on Electronics & the
Environment,SanFrancisco,Califomia,pp.219224.
[6] Sikhar Barari, Gaurav Agarwal, W.J.Zhang, Biswajit
Mahanty,M.K.Tiwari,2012.Adecisionframeworkfor
the analysis of green supply chain contracts: An
evolutionary game approach. Expert system with
Applications,Vol.39,pp29652976.
[7] S. Brink, J.C. Diehl, A. Stevels,1998 ECOQUEST, an
ecodesign self audit tool for suppliers of the
electronics industry, Proceedings of the IEEE
International Symposium on Electronics and the
Environment,pp.129132
[8] V.R.Pramod and D.K.Rawat, 2010. System modeling
of telecom service sector supply chain: a SAPLAP
analysis. Int. J. Business Excellence, Vol. 3, No. 1,
pp3864.
[9] Wang,MiaoLing,Kuo,TsaiChiandLiu,JiaWen,
2009. Identifying target green 3C customers in
Taiwan using multi attribute utility theory. Expert
SystemswithApplications,Vol.36,No.10,pp.12562
12569.
[10] Wei SY, Jinlong Z, Zhicheng LI, 1997. A supplier
selecting system using a neural network. IEEE
International Conference on Intelligent Processing
Systems,Vol.1,pp468471.
[11] Yuang, A.; KielkiewiczYuang, A., 2001. Sustainable
supply network management. Corp. Environ.
Manage.,Vol.8,No.3,pp.260268.
CONCLUSION
Green/Sustainable
Supply
Chain
Management
(GSCM/SSCM) is a relatively new green issue for the
majority of Indian industries. Research presents
practitioners with a 105 item measurement scale for
evaluating the different facets of their sustainable supply
chain practices implementation. The present empirical
study investigated the SSCM practices adopted by the
Small and Medium Scale Steel industry in India. The
pressuresordrivestoimplementSSCMpracticesandthe
relationship between SSCM practices and as well as
environmental performance were also studied. The
approach adopted in the present study included a
questionnaire. Importance of approach to sustainable
supplychainaspresentedintable1to14.Italsoassesses
the relative importance of identified approaches that
wouldaffectthesustainablesupplychainimplementation
andthedevelopment.Fromthesurveyoftheindustry,the
score is not up to the mark. Industries should more
concentratetheirstrategy.Thiswillautomaticallyimprove
thescorecardandtherebyperformance.
REFERENCES
[1] A.M.J. Gil, J.B. Jimenez and J.C. Lorente, 2001. An
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of
environmental
management,
organizational context and performance of Spanish
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[2] Bearing point 2008, Supply Chain Monitor How
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ShuPingLin,
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32

TheProceedings
Wear Resistant Self-fluxing Alloy Based TiC-NiMo and Cr2C3-Ni

Hardmetal Particles Reinforced Composite Coatings
AndreiSurzhenkov1 AhtoVallikivi1ValdekMikli2MartViljus2TimoVilgo1PriitKulu1
DepartmentofMaterialsEngineering,TallinnUniversityofTechnology,Ehitajatetee5,19086Tallinn,Estonia
CentreforMaterialsResearch,TallinnUniversityofTechnology,Ehitajatetee5,19086Tallinn,Estonia
ARTICLEINFO:
Received:14September2012/Revised:11November2012/Accepted:12November2012
Abstract:
Abrasivewear
Compositecoating
HVOF
Recycledhardmetal
Inthecurrentarticle,highvelocityoxyfuel(HVOF)sprayedwearresistantcoatingsofthecomposition65
75vol.%NiCrSiB/FeCrSiB+3525vol.%TiCNiMo/Cr2C3Niwerestudied.SelffluxingNiCrSiBandFeCrSiB
powders were supplied from Hgans AB, hardmetal TiCNiMo and Cr2C3Ni powders were obtained by
desintegrator milling at Tallinn University of Technology. Microstructure of the sprayed coatings was
investigatedbySEM,distributionofchemicalelementswasstudiedbyEDS.Vickerssurfacehardnesswas
measured at the surfaces of the coatings applying the load of 1 kgf (9.8 N), Vickers microhardness was
measuredatthecrosssectionsofthecoatingsapplyingtheloadof0.05kgf(0.49N).ASTMstandardG65
94 abrasive wear test was carried out in order to estimate the abrasive wear resistance of the coatings.
Volumetricwearofthecoatedspecimenswascalculatedaftereach60secondsoftest.Thetotalduration
ofthetestwas300seconds.Theresultsshowedthatthemicrohardnessofthehardmetalreinforcedself
fluxing alloy based coatings increased 1.1 1.2 times and the abrasive wear resistance of the respective
coatingsincreased1.11.6timesincomparisonwiththeunreinforcedcoatings,whereasCr2C3Niparticles
reinforcedcoatingsdemonstratedbetterresistancetowear.
Citation: Surzhenkov A, et al.: Wear Resistant Selffluxing Alloy Based TiCNiMo and Cr2C3Ni Hardmetal Particles Reinforced Composite Coatings , 2nd International Conference
INTRODUCTION
SelffluxingalloysarethealloysofcompositionNiCrSiFe
B, applied for the improvement of wear resistance
together with oxidation or hot corrosion [1] by thermal
spraying. Numerous researchers have reported the
enhancement of wear resistance of the selffluxing alloy
based coatings by the addition of both ceramic, such as
WC [14], B12C3 [1,2], TiC [1,2], etc., as well as hardmetal
tungsten [1,46] and chromium [79] carbides based
hardmetalparticles.Asindicatedin[5],[7]and[9],milled
hardmetal scrap can also be applied for these purposes.
However, to authors' best knowledge, no information
about the application of TiC based hardmetals for the
increaseofwearresistanceoftheselffluxingalloybased
coatings is available. In addition, relatively little attention
has so far been paid to the Cr2C3 based hardmetals as a
possible reinforcement phase of selffluxing alloy based
coatings. The current article concentrates on the
preliminarycomparativestudyofNiCrSiBandFeCrSiBself
fluxing alloy based coatings, reinforced by the TiCNiMo
and Cr2C3Ni hardmetal particles, produced from
hardmetal scrap. Microstructure, chemical composition,
surface hardness and microhardness and progress of
abrasivewearofcoatingsarestudied.
vol.% NiCrSiB + 35 vol.% TiCNiMo, 70 vol.% NiCrSiB + 30

vol.% Cr2C3Ni, 70 vol.% FeCrSiB + 30 vol.% TiCNiMo and
75vol.%FeCrSiB+25vol.%Cr2C3Ni.Particlesizeswerein
the range of (+10 45) m in case of the NiCrSiB and
FeCrSiBalloysandof(+2063)mincaseofTiCNiMoand
Cr2C3Nihardmetals.PriortosprayingtheNiCrSiBpowder
andrelatedmixturesweredriedat150Cfor6handthe
FeCrSiB and related mixtures at 200 C for 6 h. The
chemical compositions of the coatings are indicated at
Table1.
Tab.1Chemicalcompositionofpowdersandcoatings
EXPERIMENTAL
Coatings were sprayed applying the Tafa JP5000 (Praxair

Inc.)gun.TheparametersofsprayingarecarriedatTable
2. Instantly before spraying, the specimens were heated
by gun flame for 5 seconds to the temperature of about
150Ctodrythemoistureoutofthesteelsurface.
Microstructurestudies
Crosssections of the sprayed specimens were polished
and studied by the scanning electron microscope (SEM)
EVOMA15(CarlZeiss).Distributionofchemicalelements
in the sprayed coatings was studied by the energy
dispersivespectroscopy(EDS).
Alloy
164002
6AB
Preparationofspecimens
Specimens were milled from carbon steel C45 (0.45 % C,
0.65%Mn,0.035%P,0.035%S,0.40%Cr,0.10%Mo,
0.40Ni)tothedimensionsof502510mm.Priorto
thermalsprayingtheyweregritblastedwithAl2O3tothe
surfaceroughnessofRa=10,01,0m.
Highvelocityoxyfuel(HVOF)sprayingofcoatings
Two selffluxing alloy powders (164002 NiCrSiB and 6AB
FeCrSiB; both from Hgans AB) and two TiCNiMo and
Cr2C3Nibasedhardmetalpowders(desintegratormilledat
Tallinn University of Technology) were applied. The
sprayed powders were pure NiCrSiB, pure FeCrSiB, 65
33
Ni, Fe,
Cr,
Si,
B, Mn, C,
wt% wt% wt% wt% wt% wt% wt%
Bal. 2.16 7.35 3.52 1.72
6.04 Bal.
13.7
2
2.67
3.4
0.25
0.32 2.07
TiC
NiMo
70wt%TiC,20wt%Ni,10wt%Mo
Cr2C3Ni
70 wt%Cr2C3,30wt%Ni
S,
wt%
0.02
A.Surzhenkov et al.
Wear Resistant Self-fluxing Alloy Based TiC-NiMo and Cr2C3-Ni Hardmetal Particles Reinforced Composite Coatings
microcracking. However, this hypothesis needs further

research.
Hardnessmeasurements
Vickers hardness was measured at the diamond paste
polishedsurfacesofthesprayedcoatingsattheloadof1
kgf (9.8 N) using the Indentec 5030 SKV hardness tester.
Vickers microhardness of the coatings was measured at
thepolishedcrosssectionsofthespecimensattheloadof
0.05 kgf (0.49 N) applying the Micromet 2001
microhardnesstester.
Tab.2ParametersofHVOFspraying.
Oxygensupplypressure
14.5bar
Oxygenworkpressure
9.7bar
Oxygenflow
55224lpm
Kerosenesupplypressure
11.7bar
Keroseneworkpressure
8.3bar
Keroseneflow
Combustionpressure
Nitrogenpressure
a)
0.36lpm
7.1bar
5bar
Nitrogenflow
27lpm
Sprayingdistance
380mm
Abrasiveweartest
The abrasive wear resistance of coatings was tested,
applyingthestandardASTMG6594blockonring(rubber
wheel) test. The normal load was 130 N, the speed of
rotationwas3.3s1, theabrasivewasquarzsandwiththe
particle size 0.1 0.3 mm. Prior to the test, all coatings
were grinded to the thicknesses of 0.15 0.20 mm.
Hardened (850 C, water) and tempered (550 C, 1.5 h)
carbon steel C45 was used as reference material. After
each 60 s (200 s1) the test was stopped, and volumetric
wear was calculated. The total duration of the test was
300sforeachcoating.
b)
RESULTSANDCONCLUSIONS
Microstructurestudies
The microstructures of the composite selffluxing alloy
hardmetal coatings are demonstrated at Fig. 1. The
sprayedcoatingshadanalmostporefreestructure,witha
slightly bigger porosity in the case of FeCrSiB alloy based
coatings.AlsotheFeCrSiBalloybasedcoatingsexhibiteda
lessdensestructure,withanumberofevidenthorizontal
microcracksinthemicrostructure(Fig.1c,d),whileinthe
NiCrSiBalloybasedcoatingstheywerenegligibleorabsent
(Fig.1a,b).Theappearanceofsuchcrackscanbepossibly
explainedbythedifferencesinthevaluesofcoefficientsof
thermal expansion between Nibased and Febased self
fluxingalloys.Accordingtotheliteraturedata[1012],the
coefficientofthermalexpansionofNiCrSiBalloysisinthe
rangeof(1314)106K1,itisquiteclosetothevalueof
pureNi(13106K1).Takingintoaccountthatthebinder
intheappliedhardmetalsiseitherpureNiorisbasedon
Ni,thesimilaritybetweenthevaluesofthermalexpansion
coefficients should provide a relatively more favourable
stress distribution between selffluxing alloy matrix and
hardmetalparticles.Nodata,concerningthevalueofthe
thermalexpansioncoefficientvalueofselffluxingFeCrSiB
alloys could be found, however, taking into account the
relatively large Fe content in the applied material
(approximately72%),thevalueofthethermalexpansion
coefficientoftheFeCrSiBselffluxingalloyshouldbeclose
tothatofpureiron(12.0106K1).Thedifferenceinthe
values of thermal expansion coefficients between self
fluxingalloyandhardmetalscouldinducetheappearance
of thermal stresses, what, in its turn, could lead to
c)
d)
Fig. 1 Microstructure of the HVOF sprayed coatings: a
NiCrSiB + TiCNiMo, b NiCrSiB + Cr2C3Ni, c FeCrSiB +
TiCNiMo,dFeCrSiB+Cr2C3Ni.
34
The hardmetal particles are plastically deformed

(elongated)inthedirection,perpendiculartothespraying
direction. The EDS analysis revealed no dissolution of
hardmetalmaterialintheselffluxingalloy,whatisingood
correspondencewiththepreviouslyobtainedresults[7].
3.2 Hardnessmeasurements.
Nosignificanteffectofthehardmetalparticlesadditionto
the surface hardness of the sprayed coatings was
observed(Fig.2).However,onthemicroscaletheaddition
of hardmetal particles to the selffluxing alloy caused an
increase in microhardness values of the sprayed coatings
by1.11.2timesincomparisonwiththepureselffluxing
alloycoatings(Fig.3).Theeffectofmicorhardnessgrowth
was less pronounced in the case of FeCrSiB alloy based
coatings. This may be caused by the initially lower
hardmetalcontentinthesprayedcoatings,aswellasbya
lessdensestructure,asmentionedabove.
The Cr2C3Ni particles reinforced selffluxing alloy based

coatingsgenerallydemonstratedahigherwearresistance,
than the those with the TiCNiMo hardmetal particles,
despite the fact that TiCNiMo hardmetal is harder, than
the Cr2C3Ni one (1415 HV [13] and 980 HV [14],
respectively). The reason for that is not clear and needs
further investigations. 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, as
canbeseenaFig.1.
CONCLUSION
1.TiCNiMo and Cr2C3Ni hardmetal particles reinforced
NiCrSiB and FeCrSiB selffluxing alloy coatings were
successfully sprayed applying the high velocity oxyfuel
spraying.
2.FeCrSiB alloy based coatings were less dense due to
microcracking, induced by the differences in the values
of thermal expansion coefficients of the FeCrSiB alloy
andhardmetals.
3.Addition of hardmetal particles allows to increase the
microhardnessofselffluxingalloycoatingsby1.11.2
timesincomparisonwiththosewithouttheadditionof
hardmetalparticles.
4.Hardmetalparticlesallowtoincreasetheabrasivewear
resistanceofselffluxingalloysprayedcoatingsby1.1
1.6 times in comparison with the pure selffluxing alloy
coatingsandbyupto2.6timesincomparisonwithsteel
C45. Cr2C3Ni hardmetal reinforced selffluxing alloy
coatings demonstrated better abrasive wear resistance
thanTiCNiMohardmetalbasedones.
900
800
HV1, MPa
700
600
500
400
300
NiCrSiB
NiCrSiB+
TiC-NiMo
NiCrSiB+
Cr2C3-Ni
FeCrSiB
FeCrSiB+
TiC-NiMo
FeCrSiB+
Cr2C3-Ni
C45
Fig.2.Surfacehardnessofsprayedcoatings
1050
ACKNOWLEDGEMENT
950
Authors thank Dr. Maksim Antonov for the help with the
wear test. This work was supported by the Estonian
Ministry of Education and Research (targetfinanced
projectSF01400091s08).
HV0.05, MPa
850
750
650
550
REFERENCES
450
[1] Ramesh, M.R., Prakash, S., Nath, S.K., Sapra, P.K.,

Venkataraman, B., Solid particle erosion of HVOF
sprayedWCCo/NiCrFeSiBcoatings.Wear,269,34,
2010,197205.
[2] Miguel, J.M., Guilemany, J.M., Vizcaino, S.,
Tribological study of NiCrSiB coating obtained by
different processes. Tribology International, 36, 3,
2003,181187.
[3] Nurminen, J., Nkki, J., Vuoristo, P., Microstructure
and properties of hard and wear resistant MMC
coatings deposited by laser cladding. International
Journal of Refractory Metals and Hard Materials,
2009,27,2,472478.
[4] Gassmann,R.C.,Lasercladdingwith(WC+W2C)/Co
Crand(WC+WC2)/NiBSicompositesforenhanced
abrasive wear resistance. Materials Science and
Technology,12,8,1996,691696.
[5] Kulu, P., Zimakov, S., Wear resistance of thermal
sprayed coatings on the base of recycled hardmetal.
Surface and Coatings Technology, 130, 1, 2000, 46
51.
[6] Grnewald,B.,Shen,J.,Dausinger,F.,Nowotny,St.,
In: Mordike BL, editor. Laser cladding with a
heterogeneous powder mixture of WC/Co and
NiCrSiB: European conference on laser treatment of
materials(ECLAT92),1992,411416.
[7] Sarjas,H.,Goljandin,D.,Kulu,P.,Mikli,V.,Surenkov,
A., Vuoristo, P., Wear resistant thermal sprayed
composite coatings based on iron selffluxing alloy
and recycled cermet powders. Materials Science
(Mediagotyra),18,1,2012,3439.
350
250
NiCrSiB
NiCrSiB+ NiCrSiB+
TiC-NiMo Cr2C3-Ni
FeCrSiB FeCrSiB+ FeCrSiB+

TiC-NiMo Cr2C3-Ni
C45
Fig.3.Microhardnessofsprayedcoatings
Abrasivewearresistance.
AscanbeseenfromFig.4,theabrasivewearresistanceof
selffluxing alloy based coatings increases by 1.1 1.6
timeswiththeadditionofhardmetalparticles.Thegrowth
of wear resistance in comparison with the reference
material (steel C45) is up to 2.6 times. Also it should be
emphasized that the pure NiCrSiB and FeCrSiB based
coatings, as well as the NiCrSiB+TiCNiMo coating were
obviously worn through by the end of the test, as their
wearratesweresimilartothoseofthereferencematerial.
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 3Ni
F eC rS iB +C r2C 3Ni
12
mm3
10
8
6
4
2
0
1min
2min
3min
4min
5min
Fig.4.Abrasivewearresistanceofsprayedcoatings
35
A.Surzhenkov et al.
A.Surzhenkov et al.
[11] Deloro 50EXV Technical Data, available at

http://stellite.com/Portals/0/pdf/Datasheets/Deloro
%2050%20EXV%20DS0523108%20(S%20R0808).pdf,
07.09.2012.
[12] Deklaagpoeders voor thermisch spuiten, available at
www.vatis.be/showpage.asp?iID=74,07.09.2012.
[13] Pirso, J., Viljus, M., Juhani, K., Kuningas, M., Three
body abrasive wear of TiCNiMo cermets. Tribology
International,43,12,2012,340346.
[14] Hussainova,I.,Someaspectsofsolidparticleerosion
ofcermets.TribologyInternational,34,2,2001,89
93.
[8] Mtt, A., Kanerva, U., Vuoristo, P., Structure and

tribological characteristics of HVOF coatings sprayed
from powder blends of Cr2C325NiCr and NiCrSiB
alloy.JournalofThermalSprayTechnology,20,12,
2010,366371.
[9] Kulu,P.,Tarbe,R.,ikin,A.,Sarjas,H.,Surenkov,A.,
Abrasive wear resistance of recycled hardmetal
reinforced thick coating. Key Engineering Materials,
527,2013,185190(inpress).
[10] Lille,H.,Ko,J.,Kulu,P.,Pihl,T.,Residualstressesin
different thermal sprayed coatings. Proceedings of
Estonian Academy of Science and Engineering,2002,
8,3,162173.
36

TheProceedings
Magnetically-Impelled Arc Butt Welding for Manufacture of

Automobile Hollow Parts of Mass Production
MohanSreenivasan1BolluBaskaran2VladimirKachinskiy3SergeyKuchukYatsenko3
1
GKMCollegeofEngineering&Technology,Chennai,India,Email:sreenivasansaim@gmail.com
EtaWeldTech(I)PrivateLimited,Coimbatore,India
TheE.O.PatonElectricWeldingInstituteofNASofUkraine,Kiev,Ukraine
ARTICLEINFO:
Category:Application
Abstract:
Magneticallyimpelledarcbuttwelding
Automobileparts
Jointformation
Technologyofwelding
Magnetically Impelled Arc Butt (MIAB) welding is a forge welding technique which generates uniform
heatingatthejointthroughrapidrotationofanarc.Theprocessdoesnotusefillermaterialandanysurface
impuritiesareextrudedduringtheforgingphase.OvertherecentyearsthetechnologyofMIABweldingof
thenewgenerationofpartsofautomobileindustryhasbeendeveloped.Thisrotationresultsfromforces
imposedonthearcbyanexternalmagneticfield.MIABweldingisusedextensivelyinEurope,butseldom
utilized in India. The MIAB equipment is robust and relatively simple in design, and requires low upset
pressurescomparedtoprocesseslikeFrictionwelding.
Citation:SreenivasanM.etal.MagneticallyImpelledArcButtWeldingforManufactureofAutomobileHollowPartsofMassProduction,2ndInternationalConferenceManufacturing
Engineering&Management2012,(2012),p.3740,ISBN9788055312163
INTRODUCTION
MD1, Figure 3. Technical characteristics of welding
machines are given in Table 1. Chemical composition of
partsispresentedinTable2.
Highefficiency and energysaving processes of welding,

assuring the quality of parts, will find a great demand at
the automobile plants. The development of new
technologies will be challenging for achievement of the
higher labor productivity. At the E.O.Paton Electric
Welding Institute of the NAS of Ukraine the technology
andequipmenthavebeendevelopedforthemagnetically
impelledarcbuttwelding(MIABwelding),whichiswidely
usedintheautomobileindustryofUkraine.Since1994the
pneumatic springs and shockabsorbers, Figure 1, welded
by MIAB welding are manufactured at Ukrainian
automobileplants[1;2;3].Duringthisperiodmorethan4
millionofweldedjointsweremade.
Fig.2MachineMD101
Fig.1 Figure 1. Part of OD 19 x 1.7 mm pneumatic spring

andOD53x1.8mmshockabsorber.
Weldabilityofcompacthollowautomobileparts,suchas
OD 22 x 2.2 mm piston rod, OD 40 x 2.2 mm shock
absorbersandOD34x6mmtorquerod,wasinvestigated.
Basic requirements, specified for the work, were to
develop the highlyefficiency 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. The works were
performed using welding machines MD101, Figure 2, and
Fig.3MachineMD1
37
M. Sreenivasan, et al.
Magnetically-Impelled Arc Butt Welding For Manufacture of Automobile Hollow Parts of Mass Production
Machine
Type
Diameter
ofpipes,mm
Wall
thickness,
mm
Efficiency,
welds/h
Upsetting
force,kN
Consumed
power,
kVA
Mass,
kg
Tab.1 Technical characteristics of machines for pipe

welding.
MD101
1061
15
60
40
30
230
MD1
1861
16
60
60
45
190
pistonrodandshockabsorberwerecarriedoutindevice
M400ofLecocompanyat1Nloadand100mpitch.To
reveal the microstructure of welded joint, the chemical
etchingby4%alcoholicsolutionofnitricacidwasused.
PISTONRODS
The part of a piston rod represents a pipe of 300 mm
length,towhichrodhollowpartswith60mmlongthread
are weldedon on both sides. Pilot technology of MIAB
weldingofpipewithhollowrodshasbeendevelopedasa
result of carried out investigations. Figure 4 shows the
weldedjointmadebyMIABwelding.
Tab.2Chemicalcompositionofautomobileparts
Massfractionofelements,%
C
Si
Mn S
Cr
Ni
Cu
Compositionofpart
0.12 0.02
0.08 0.02
W
0.1
Fig.5Partofpistonrodafterrupturetests
Macrosections, Figures 6, were manufactured from
welded joints of the piston rod part. Width of heat
affected zone was 2.22.4 mm. Welded joint does not
require auxiliary operations after completion of the
welding process and flash removal. Method of MIABW
welding allows, when necessary, producing the height of
weldreinforcementupto0.5mm.
Upsetting
force,kN
Part
shortening,
mm
Consumed
power,kW
OD
22x2.2
Shock
OD
absorber 40x2.2
Torque
OD
rod
34x6.2
Timeof
welding,s
Diameter,
mm
Description
ofpart
MaintechnologicalparametersofweldingthepartsofOD
22 x 2.2 mm piston rod, OD 40 x 2.2 mm shockabsorber
andOD34x6mmtorquerodarepresentedinTable3.
Tab.3Maintechnologicalparametersofwelding
Pistonrod
3.7
21
2.1.2.3
6.1
4.8
31
3.73.9
6.7
13.2
40
77.5
7.2
Fig.6Macrosectionofweldedjointofleftpistonrod
The carried out metallographic examinations of welded
joint of the piston rod part showed the following results.
Themeasurementofdistributionofmetalhardnessinthe
zone of welded joint of the piston rod was performed in
thedirectionfromthepipetotherodpart,Figure7.
Mechanical tests of welded joints were performed in

accordance with procedures accepted at the automobile
plants.Theyincludefullscalerupturetestsandalsolocal
bending of segments of circumferential welds.
Metallographic examinations of welded joints of parts of
Fig.7 Distribution of metal hardness in the welded joint

zone
38
0.22
0.04
0.07
0.04
0.08
0.01
0.05
0.07
0.05
0.17
0.17
0.05
0.07
0.02
0.011 0.012 0.015

0.011 0.012
0.006 0.015
0.90
1.23
0.05
0.004 0.004 0.004

0.018 0.004
1.01
0.008 0.010
Torquerod
OD346mm
0.56
Bushing
0.91
0.55
0.55
Tube
0.080 0.107 0.174
Shockabsorber
OD402.2mm
0.162 0.152
Tenon
0.22
0.20
Head
Piston
0.170 0.175 0.194
Tube
Tube
0.136 0.146
0.18
0.32
Pistonrod
OD222.2mm
Fig.4AutomobileasweldedpartofOD22x2.2mmpiston
rod
Welded joints were subjected to rupture and bend tests.
Theruptureforcewas12900kg,thefractureoccurredon
the pipe parent metal at 140 mm distance from the butt
that proves the high mechanical strength of the joint,
Figure5.Bendtestsshowedhighductilepropertiesofthe
joint.
Magnetically- Impelled Arc Butt Welding For Manufacture of Automobile Hollow Parts of Mass Production
M. Sreenivasan et al.
Mechanical tensile and bend tests of welded joints of a

pistonrodandshockabsorberprovethatthestrengthof
joints is equal to that of the parent metal of parts. Bend
testsaresevereforthistypeofjoints.Theperformedfull
scalemechanicalbendandrupturetestsofpartsofpiston
rodandshockabsorbershowedthatductilepropertiesof
the welded joint are at the level of properties of the
parentmetal.Asaresultofcarriedoutinvestigationsthe
technology of MIAB welding of the shockabsorber part
has been developed. Macrosection, Figure 11, was
manufactured of the shockabsorber welded joint. Width
of heataffected zone was 2200 2400 m. Welded joint
does not require auxiliary mechanical operations after
completion of the welding process. Metallographic
examinationsofweldedjointofpartsofshockabsorberof
40x2.2 mm diameter showed the following results.
Measurement of metal hardness distribution in welded
jointzonewasmadeinthedirectionfrompipeintopart,
Figure12.
The ferrite decarbonized band on the joint line is absent,

Figure 8. Metal hardness on the joint line is HV 2640
2970 MPa. Defects were not revealed in the joint zone.
The structure of HAZ overheating zone represents a
mixture of pearlite, bainite (HV 3060 3110 MPa) and a
small amount of ferrite (HV 2540 2610 MPa), Figure 8.
The width of overheating zone is 550 600 m. Further
the structure is refined, the amount of bainite is
decreased, the amount of a pearlite component is
increased. Width of HAZ is 2200 m. The structure of
parent metal of pipe is finegrained, ferrite (HV 2020
MPa), pearlite (HV 2120 2370 MPa) with a clearly
expressed texture of rolled metal. The structure of HAZ
overheating area of rod part is bainiteferrite (HV 2710
3210MPa),Figure8,withofoverheatingareais700m.
The structure of rod part parent metal is bainiteferrite
withhardness(HV27903090MPa).
Fig.8Lineofweldedjoint
Shockabsorbers
Fig.11 Macrosection of welded joint of shockabsorber

part
Metallographic examinations of welded joint of parts of
shockabsorber of 40x2.2 mm diameter showed the
following results. Measurement of metal hardness
distribution in welded joint zone was made in the
directionfrompipeintopart,Figure12.
ChemicalcompositionofpartofshockabsorberofOD40
x2.2mmsizeisgiveninTable1.Thepartrepresentsapipe
of 300 mm length, the inner part of which is coated by
chromium of 0.02 mm thickness, a hollow bushing piece
with60mmlongthreadisweldedonononeside.Figure9
showedaweldedjointmadebyMIABwelding.
Fig.12Distributionofmetalhardnessinweldedjointzone
Theferritedecarbonizedbandonthelineofjointofpipe
and torque rod is absent, Figures 13. Metal hardness on
the joint line is HV 2700 2850 MPa. Defects in the joint
zonewerenotrevealed.ThestructureofHAZoverheating
area of pipe metal consists of pearlite (HV 2570 2650
MPa),bainite(HV30303210MPa)andasmallamount
offerrite.Widthofoverheatingareais500m.HAZlength
is 2300 m. The structure of HAZ overheating area of
metaloftailpiecepartrepresentsamixtureofferriteHV
21902210MPaandpearliteHV23402390MPa.Ferrite
of different morphological forms is observed in the
structure. Width of overheating area is 500 m. HAZ
length is 1200 m. The pipe parent metal has a ferrite
pearlitestructurewithaclearlyexpressedtextureofrolled
metal,HV22102320MPa.Thestructureofparentmetal
ofbushingrodpartisferritepearliteHV19902210MPa
withagreatdominationofaferritecomponent.
Fig.9Weldedjointofshockabsorber
Mechanical rupture and bend tests were performed. The
rupturetestsshowedthatjoint strengthisatthelevelof
characteristics of the parent metal of the tail piece part,
Figure 10. The rupture force was 12200 kg. Bend tests
showedthehighductilepropertiesofweldedjoint.
Fig.10 Welded joint of shockabsorber part after rupture

tests.
39
M. Sreenivasan, et al.
Magnetically-Impelled Arc Butt Welding For Manufacture of Automobile Hollow Parts of Mass Production
compressionwereperformedusingjointswithaflash.The
presence of flash, causing the concentration of stresses,
did not decrease the values of cyclic tests. This is
stipulated by the fact that the finegrain structure with
high tough properties is observed in the place of an
increased concentration of stresses at the boundary of
weld reinforcement. As a result of carried out
investigations the technology of MIAB welding of part of
theOD34x6mmtorquerodoftruckshasbeendeveloped.
CONCLUSIONS
Fig.13Lineofweldedjoint
Itwasfoundasaresultofinvestigationsthatthewelded
joints of parts of piston rod and shockabsorber have no
structures, changing significantly the properties of metal
as regards to the parent metal. The bainiteferrite
structure is dominated in the structure of welded joints.
The peculiar feature of structure of welded joints is the
absenceofacoarsegrainarea.
1.The carried out fullscale mechanical rupture tests of

parts of piston rod and shockabsorber prove the high
mechanical strength of welded joint at the level of main
characteristicsoftheparentmetal.
2.Thecarriedoutmechanicalbendtestsofpartsofpiston
rod and shockabsorber in accordance with procedure
accepted at the automobile plant prove the high ductile
propertiesofthejoint.
3. The carried out cyclic fatigue tests of torque rod parts
showedthatthefatiguefractureofsamplesofthetorque
rodoccurredinparentmetal.
4.Vickershardnessofweldedjointmetalisincompliance
with hardness of parent metal of parts that proves the
highgradientoftemperaturefieldinMIABwelding.
5.The welded joints have no hazardous hardened
structures which decrease the ductility and strength of
joints.
6.TechnologyofweldingtheautomobilepartsofOD22x
2.2mmpistonrod,OD34x6mmtorquerodandOD40x
2.2mmshockabsorberhasbeendeveloped.
7. The developed technology can be used in mass
productionwherethehighlaborproductivityisrequired.
8.Lowpowerconsumption.
9.Noweldingconsumablesarerequired.
10.Weldsarefreefrominclusionsandimpurities.
11.Anautomatedprocessenablingtheresultingweldsto
behighlyreproducible.
12.Thecomponentsarenotrotatedsothealignmentcan
bemaintained.
13. Welds a wide variety of materials including dissimilar
combinations.
14.Canbeinterfacedwithautomatichandlingsystems.
15.Reducesweldtimebyupto90%
Torquerod
Thechemicalcompositionofpartsoftorquerodisshown
inTable1.Thetorquerodconsistsofapipeand2heads.
Pipematerialissteel20,headsareofsteel30.Aswelded
partsofthetorquerodweresubjectedtofatiguetestsina
special stand at tensioncompression symmetric cycle,
Figure14.ResultsoftestsaregiveninTable4.
Fig.14Cyclictestsofweldedpartoftorquerod
Tab.4 Results of testing the torque rod parts at tension
compressionsymmetriccycle
Load,kN
Specific
load,
MPa
Numberof
cycles
before
fracture
70
133.0
914000
2
3
60
50
114.0
95.0
2480100
3027500
45
85.5
10
No.of
sample
REFERENCES
Placeof
fracture
[1] KuchukYatsenko S.I., Krivenko V.G., Kachinsky V.S.,

IgnatenkoV.Yu.Machineformagneticallyimpelledarc
buttwelding,PatentofUkraineNo.94128094(3/4663)
of20.12.94.
[2] Kachinsky V.S., Ignatenko V.Yu, et al. Magnetically
impelledarcbuttweldingoftubularparts(equipment
and technology), Avtomaticheskaya Svarka, No.7,
1997.
[3] Kachinsky B., Ignatenko V., Koval M. Magnetically
impelled arc butt welding of hollow and solid parts.
p.3044. Exploiting solid state joining, 1314.09.1999,
TWI,GreatAbington,Cambridge,UK.
Inhead
body
Thesame
Thesame
Without
fracture
The fracture of the torque rod part after tension

compression tests was in parent metal of a tip. The tests
of welded joints at symmetric cycle of tension
40

TheProceedings
Study on Polyamide 12/clay Nanocomposites by Melt-Intercalation

Process
PeroRaos1JosipStoji1AlenaKalendova2DagmarMerinska2Mladenercer3
1
UniversityofOsijek,MechanicalEngineeringFacultyinSlavonskiBrod,Croatia,Email:pero@raos.hr,jstojsic@sfsb.hr
2
TomasBataUniversityinZlin,FacultyofTechnology,Zlin,CzechRepublic,Email:kalendova@ft.utb.cz,merinska@ft.utb.cz
UniversityofZagreb,FacultyofMechanicalEngineeringandNavalArchitecture,Zagreb,Croatia,Email: mladen.sercer@fsb.hr
ARTICLEINFO:
Received:13October2012/Revised:21October2012/Accepted:13November2012
Abstract:
Polymernanocomposite
Montmorillonite
PA12
Nanocomposites are multiphase materials where at least one of the constituent has one dimension less
than 100 nm. For its characteristic properties nanocomposites are nowadays increasingly being used in
technique,andcertainlywilltakeasignificantshareinmaterialsproductioninthefuture.Polymerlayered
silicatesareanimportantclassofnanocompositematerials.Thesestructuresmaybeformedbyannealing
layeredsilicateparticles,whosesurfaceshavebeenchemicallymodifiedtorenderthemorganophilic,with
apolymermelt.Thisprocessiscalledmeltintercalation.Duringintercalation,polymermoleculesleavethe
bulkmeltandenterthegalleriesbetweenthesilicatelayers.Thepaperdealswithpreparationofpolyamide
12/clay nanocomposites by a meltintercalation process. We studied several types of modified and
unmodified montmorillonite clays in various concentrations. The influence of compounding conditions,
screw rotation speed and compounding time were investigated too. The aim of the investigation was to
determinetheoptimumcombinationofcompoundingparameterswhichassuresatisfylevelofintercalation
and uniform distribution of nanofillers, and in the same time does not lead to thermal degradation of
nanocomposite.
Citation:RaosP,etal.Studyonpolyamide12/claynanocompositesbymeltintercalationprocess,2ndInternationalConferenceManufacturingEngineering&Management2012,(2012),
p.4143,ISBN9788055312163
INTRODUCTION
ofmontmorilloniteis2:1Thecrystallatticeof2:1layered
silicates (or 2:1 phyllosilicates), consists of two
dimensional layers where a central octahedral sheet of
alumina is fused to two external silica tetrahedra by the
tip, so that the oxygen ions of the octahedral sheet also
belongtothetetrahedralsheets,asshowninFig.1.[2]
Nanocomposites are materials which study had been

started in 90th years of last century, but manufacture of
nanoscale materials is at least a 100 year old industry
(particles of carbon black as fillers in automotive tyres).
The field of nanotechnology is one of the most popular
areasforcurrentresearchanddevelopmentinbasicallyall
technicaldisciplines.Seekingfornewmaterialswithbetter
properties, scientists are lately more and more dealing
with nanocomposites. By definition, the nanocomposites
arematerialsinwhichatleastonephaseisinnanometer
dimensions, (dimensions of the particle, platelet or fibre
modification are in the range of 1100 nm), whereby is
achieved higher specific interfacial area. Therefore the
properties of obtained nanocomposites depend more on
interactions at the phase boundary than on the phase
itself.
POLYMERNANOCOMPOSITES
Polymernanocompositesarecomposedofpolymermatrix
andnanofiller.Typicalnanofiller/reinforcefillerincludes:
layered filler (with nanometre layer thickness and sheet
structure, fibre reinforcing filler (carbon nanotubes and
nanofibres) and nanoparticles (SiO2 nanometre
dimensionsparticles).
Polymer/layeredsilicatenanocomposites
Layeredsilicatesusedinthesynthesisofnanocomposites
are natural or synthetic minerals, consisting of very thin
layersthatareusuallyboundtogetherwithcounterions.
For decades, the clay minerals in the sheet form of
nanometer thickness are used as filler during the
productionofpolymernanocomposites.Forthispurpose,
today are most commonly used natural clay minerals:
montmorillonite,hectoriteandsaponite.[1]Thenameof
MontmorilloniteisderivedfromthedepositMontmorillon
whichisinFrance.Montmorilloniteisclaymineralwhichis
classified in class of dioctahedral smectite. The structure
Fig.1Structureofa2:1layeredsilicate[2]
Thethicknessofsuchlayerisintheorderofmagnitude1
nmandtheblankbetweennearbylayersisabout0,3nm.
The reason why the clay is used to produce
nanocomposites is very high specific layer surface, more
2
than 100 m per gram, which allows, together with very
small mass ratios (26%), uniformly dispersed filler in the
polymer matrix with the large interactive matrixfiller
surface that result in improvements of the obtained
compositeproperties.
41
P. Raos, et al.
Study on Polyamide 12/clay Nanocomposites by Melt-Intercalation Process
organicallymodifiednanometerscale,layeredmagnesium
aluminum silicate platelets. The silicate platelets that the
additivesarederivedfromare1nanometerthickand70
150nanometersacross.Theplateletsaresurfacemodified
with an organic chemistry to allow complete dispersion
into and provide miscibility with the thermoplastic
systemsforwhichtheyweredesignedtoimprove
Polymernanocompositesreinforcedwithcarbon
nanotubes
Carbon nanotubes (CNTs) are ideal fillers for polymer
composites due to their high Youngs modulus combined
withtheirlowdensity(1,3g/cm3)andgoodelectricaland
thermal conductivity. The very high aspect ratio (length/
diameter)oftheCNTsmakesitlikelythattheadditionofa
small amount(5 wt%) of CNTs strongly improves the
electrical thermal and mechanical properties of the
polymermatrix.[3]Unlikeothercarbonmaterialssuchas
graphite or diamond, carbon nanotubes (CNT) are one
dimensional carbon materials where the ratio L /D is
greaterthan1000,anditsdiameterisinnanometerscale.
[4]Dependingonthemanufacturingprocess,todaythere
are nanotubes with one (SWCNTs) or more walls
(MWCNTs)(Fig2.).
Fig.2 Conceptual diagram of singlewalled carbon

nanotube (SWCNT) (A) and multiwalled carbon nanotube
(MWCNT)[5]
Fig.3 Conceptual diagram of singlewalled carbon

nanotube (SWCNT) (A) and multiwalled carbon nanotube
(MWCNT)[5]
PRODUCTIONOFPOLYMERNANOCOMPOSITESBY
MELTINTERCALATIONPROCESS
Tab.1 Performance of Eco Procurement [Factor 1]

Themostcommonandsimplemethod,particularlyuseful
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
layersistheseparationanddispersalofanindividuallayer
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
occurdependingonthestrengthofinterfacialinteractions
(Figure3b).Intheabovementioneddependencecanalso
occur stratified nanocomposite where the clay layers are
completelyseparatedandevenlydispersedinthepolymer
matrix (Figure 3c). Stratified polymer composite is
preferred because it produces the largest matrixfiller
contact area, which leads to the best nanocomposite
properties.
Value
Unit
TensileModulus
TensileStrength
Charpyimpactstrength
(+23C)
ShoreDhardness(15s)
Meltingtemperature
(10C/min)
Density(lasersintered)
1650
48
MPa
MPa
Test
Standard
ISO5271/2
ISO5271/2
53
kJ/m
ISO179/1eU
75
176
930
kg/m
ISO868
ISO11357
1/3
EOSMethod
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,
synergisticflameretardantandbarrier.
Tab.2TypicalCloisiteproperties
INFLUENCEOFMIXINGPARAMETERSAND
MONTMORILLONITETYPEONTHERMAL
DEGRADATIONOFPA12/CLAYNANOCOMPOSITE
Materials
Nanofiler
Closisite
+
Na
Closisite
10A
Closisite
30B
Closisite
93A
MaterialusedforthenanocompositematrixisPA12inthe
powder form (PA 2200 Balance 1.0 made by Eos
Company).Thismaterialisusedfortheproductionoflaser
sintered fully functional products, which are replacing
typical injection moulding products due to their excellent
mechanical properties. The main material properties are
giveninTable1.Cloisite10A,Cloisite30B,Cloisite93Aand
CloisiteNa+ofSouthernClayProductsarethenanofillers
used in the experiment. Cloisite additives consist of
42
Properties
Organic
Modifier
Modifier
concentration
2MBHT
MT2EtOH
M2HT
125meq/100g
clay
90meq/100g
clay
95meq/100g
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.3TypicalDryparticlesizes(byvolume)[8]
Nanofiler
+
Closisite Na
Closisite 10A
Closisite 30B
Closisite 93A
10% less
than:
2
2
2
2
50% less
than:
6
6
6
6
Designofexperiment
Polyamide 12 and nanofiller were meltcompounded in a
HAAKE minilab twin screw extruder. The operating
temperature was 200 C. The screw speed was in range
from 11 to 129 min1 and mixing time from 3 to 36 min.
Theamountofnanofillerwascalculatedtobefrom0,95to
11wt%ofCloisiteinthewholemixture.Theaimofthe
investigationwastodeterminetheoptimumcombination
of compounding parameters and the optimal nanofiller
which assure satisfy level of intercalation and uniform
distributionofnanofillers,andinthesametimedoesnot
leadtothermaldegradationofnanocomposite.
90% less
than:
13
13
13
13
Equipment
Nanocomposite compounds are made on the laboratory
twinscrew extruder HAAK Minilab that is intended to
compound nanocomposites and can be used for
rheological investigations. The major advantage of this
deviceisthatitworkswithsamplesof5gramsize,sothat
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.
Thesystemisbasedonaconical,twinscrewcompounder
with an integrated backflow channel. Due to the channel
andabypassvalve,theresidencetimeiswelldefined.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
partofthemainexperimentthathastheaimtodetermine
changes(improvement)inthePA12propertiesreinforced
with nanoclay Cloisite (10A, 30B, 93 A). Also, the
experiment has been conducted to detect an optimal
choiceofparameters(mixingtime,mixingspeed,amount
of nanofiller) in nanocomposite preparation and will be
reportedindetailsinpapersthatfollow.
REFERENCES
[1] M. Ivankovi, Polimerni nanokompoziti, Polimeri
28(2007)3,pp.156167
[2] S.Pavlidou;C.D.Papaspyrides,Areviewonpolymer
layeredsilicatenanocomposites.ProgressinPolymer
Science33(2008),pp.11191198
[3] O.Valentino,M.Sarno,N.G.Rainone,M.R.Nobile,P.
Ciambelli,H.C.Neitzert,G.P.Simon,Influenceofthe
polymer structure and nanotube concentration on
the conductivity and rheological properties of
polyethylene/CNT composites, Physica E40 (2008)
24402445.
[4] P.C. Ma; N.A. Siddiqui; G. Marom; J.K. Kim,
Dispersionandfunctionalizationofcarbonnanotubes
for
polymerbasednanocomposites:A
review,
Composites:PartA41(2010),pp.13451367
[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&InterfaceScience6(2001),pp.464470
[7] EOS GmbH, Electro Optical Systems, Mnchen,
http://eos.materialdatacenter.com/eo/en,
16.06.2011.
[8] Rockwood Additives LTD., Product Bulletins
http://www.rockwoodadditives.com/product_bulleti
ns.asp
Fig.4HAAKEMiniLabtwinscrewcompounder
43
RegularSection|
inalphabeticalorder|
"Mostpeoplesaythatitistheintellectwhichmakesagreatscientist.
Theyarewrong:itischaracter."
AlbertEinstein

TheProceedings
Simulation Based Layout Design

EuikoogAhn1DaeS.Chang2SangC.Park3
1
DepartmentofIndustrialEngineering,AjouUniversity,San5,WoncheonDong,YeongtongGu,Suwon443749,Email:euikoog@gmail.com
DepartmentofIndustrialEngineering,AjouUniversity,San5,WoncheonDong,YeongtongGu,Suwon443749,Korea,Email:webmacome@ajou.@ajou.ac.kr
DepartmentofIndustrialEngineering,AjouUniversity,San5,WoncheonDong,YeongtongGu,Suwon443749,Korea,Email:scpark@ajou.ac.kr
2
3
ARTICLEINFO:
Received:21February2012/Revised:15September2012/Accepted:30October2012
Abstract:
Layoutdesign
Assemblyline
Manufacturingsystem
Thispaperproposesamethodologytodesignaplantlayoutbyusingthesimulationtechnology.Inorderto
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
automaticallyremodeled.Theproposedmethodforsimulationbasedlayoutdesigninthispaperallowsthe
layoutdesignertoswiftlygenerateassemblylineswithconsiderationofkeyfactors.Fortheimplementation
oftheproposedlayouteditor,thispaperemploysDiscreteEventSystemsSpecifications(DEVS)formalism.
Thelayouteditorcanbemodeledandsimulatedforinitiallayout.Thisisrecommendedtheeditablelayout
byeachcase.
Citation:AhnE,ChangDS,ParkSC. SimulationbasedLayoutDesign,2ndInternationalConferenceManufacturingEngineering&Management2012,(2012),p.4448,ISBN97880553
12163
INTRODUCTION
method for reconfigurable manufacturing systems. Also,
Souilah[8] presented methodology for the manufacturing
systemslayoutdesignproblemusingsimulatedannealing.
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
commercialsoftwarewereperformed[9,10].M.Iqbalet
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
commercialsimulationtoolsneedmuchtimeconsumption
forhighfidelityofproductionlines.Inaddition,studiesfor
automotive layout design method were performed. Jhon
etal[12]presentedthepartialimplementationofablock
based layout editor and the basic research on layout
compactionsystems.ChrisJ.etal[13]proposesageneric
methodologythatprovidesasystematicwaytodesignan
optimallayoutforalltypesofautomatedfacilities.Parket
al [14] presented automatic design method of assembly
sequence modeling by integrating assembly feature
information based on the ontology framework. These
studiesrepresentthesimpleproductionlines.Hence,the
creationofcomplexlayoutisgreatlyrestricted.
Internationalcompetitionhasheightenedtheneedtohigh
quality and low cost products that can complete in the
global marketplace. To remain competitive, companies
mustnotonlycontinuetoimprovetheirproducts,butalso
strive to improve production systems continuously [1].
Factory layout involves the arrangement and selection of
machines and material handling path, material handling
devices,resultinginreductionincostandtimeinvolvedin
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)techniquesareneeded.Simulationisan
essentialtoolforthedesignandanalysisofmanufacturing
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 AutoMod, have been widely accepted in
industry;however,theyarefocusedontherepresentation
highfidelityofproductionsystems.Thus,thesetoolsneed
muchefforttomaster.Thereforelayoutdesignerswantto
create easier and faster simulation tools. The main
objectiveofthisstudyistodevisesimulationbasedlayout
designmethod.Forimplementation,thispaperiswritten
using the Microsoft Visual Studio 2010 MFC (Microsoft
FoundationClass).Theoverallstructureofthepaperisas
follows: Section 2 presents the related works, while
Section3demonstratestheapproaches.Section4givesa
detaileddescriptionoftheeditablelayoutdesignmethod.
Section 5 implemented layout editor. Finally, Section 6
concludesthepaperandoutlines.
APPROACH
This paper proposed simulation based layout design
method which supports the decision making by layout
designerbasedontheirexperienceandknowhow.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
RELATEDWORKS
The research for layout design in the area of
manufacturingsystemisquiteextensive.Saifallahetal[6]
reviewed of emerging trends in design of next design
factory layout. Yoram et al [7] proposed the layout
44
E.Ahn, DS. Chang, SC. Park
hierarchical,modularform.
Fig.3Nodeprocessforsuggestedlayoutsimulation
LAYOUTDESIGNMETHOD
DEVSatomicmodelforlayouteditor
As mentioned in the previous section, the proposed
simulation model consists of five nodes. For the
implementation of the model, we employed the DEVS
formalism. The source node creates parts according to
defined inter arrival time by user. The source node must
be connected either transport node or buffer node. The
buffer node means waiting operation of part. Part is
waiting for buffer node until the connected work node is
completed. The transport node is the operation which is
the moving part. The work node means the operation,
such as assemble the part. Finally, the sink node means
the operation for drain of end product. This paper
assumes infinity capacity of transport and buffer node.
Figure 4 shows the state transition diagram of five
nodes.
Fig.1Layoutdesignprocess
Withintheformalism,onemustspecifytheatomicmodel,
basic models from which larger ones are built. Formally,
anatomicmodelMisspecifiedby7typle:
M=<X,S,Y,int,ext,,ta>(1)
Where:
X:inputeventsset;
S:sequentialstatesset;
Y:outputeventsset;
int:SS:internaltransitionfunction;
ext:Q*XS:externaltransitionfunction
Q={(s,e)|sS,0eta(s)}:totalstateofM;
:SY:outputfunction;
ta:SReal:timeadvancefunction
Thefourelementsinthe7tuplenamelyint,ext,and
ta are called characteristic functions. Figure 2 shows the
exampleofatomicmodel[17].
Fig.2Theexampleofstatetransitiondiagram
Thelayouteditorconsistsofnode,partandlink.Thenode
means the object for operations (convey, store, machine
andsoon).Thenodeconsistsoffivenodes:sourcenode,
transport node, buffer node, work node, sink node. Part
means the material for product. Part becomes finished
product by sequence of operation. In addition, the link
means to connect between nodes. Figure 3 shows the
relationshipbetweennodes.Proposedsimulatorconsider
key factor for factory operation. Therefore, layout
designer are able to easy and quick modeling of factory
layoutusinglayouteditor.
Fig.4Atomicmodeloffivenodes
45
Methodofeditablelayoutdesign
Inthissectionweproposedfoureditablelayoutsthrough
situationoftransportandbuffernode.Figure5illustrates
basiclayout.
length, unification of transport node and decrease the

velocity in transport node. The editable input factor for
buffernodeisfollows.Increasethenumberofconnected
transportnode,increasethenumberofconnectedsource
node,anddecreasethecreationtimeofpartinconnected
source node. The editable output factor for buffer node
are decrease the number of connected work node,
decrease the processing time and set up time in
connected work node. Figure 7 describes editable layout
forcase2.
Fig.5Basiclayout
If capacity of transport and buffer node is infinite, it
represents four kinds of abnormal situation of material
flow in the factory. In the case of that the number of
accumulated part is over the reasonable part capacity in
both transport node and buffer node, it is case 1. In the
caseofthatthenumberofaccumulatedpartisbelowthe
reasonable part capacity in both transport node and
buffer node, it is case 2. If the number of accumulated
part in the transport node is below the reasonable part
capacity,whereasthenumberofaccumulatedpartinthe
buffernodeisoverthereasonablepartcapacity,itiscase
3. If the number of accumulated part in the transport
node is over the reasonable part capacity, whereas the
number of accumulated part in the buffer node is below
thereasonablepartcapacity,itiscase4.Iftransportnode
stateisabnormal,itshouldbeeditinginputfactor,output
factor and attribution of transport node. The editable
input factor consist of the number of connected source
node, time of creation connected source node, the
number of connected work node, processing time
connected work node and set up time connected work
node. The editable output factor is the number of
connectedbuffernode.Theeditableattributearelength,
unify processing and parallel processing. If buffer node
state is abnormal, it should be editing input factor and
output factor. The editable input factor consist of the
number of connected source node, time of creation
connected source node, the number of connected work
node, the number of connected transport node. The
editableoutputfactorarethenumberofconnectedwork
node, processing time connected work node and set up
time connected work node. Figure 6 describes editable
layoutforcase1.
Fig.7Editablelayoutofcase2
Theeditableinputfactorfortransportnodeisasfollows:
Decreasethenumberofconnectedsourcenode,increase
the creation time of part in connected source node,
decrease of work node and increase the processing time
and setup time of part in connected work node. The
editable output factor is increased the number in
connected buffer node. The editable output factor is
increased the number in connected buffer node. The
editable attribute for transport node are decreased of
length,parallelprocessingoftransportnodeandincrease
the velocity in transport node. The editable input factor
for buffer node is follows. Decrease the number of
connected transport node, decrease the number of
connectedsourcenode,andincreasethecreationtimeof
partinconnectedsourcenode.Theeditableoutputfactor
for buffer node are increased the number of connected
work node, increase the processing time and set up time
in connected work node. Figure 8 shows editable layout
forcase3.
Increasethenumberofconnectedsourcenode,decrease
addition of work node and decrease the processing time
editable output factor is decreased the number in
decrease the number in connected buffer node. The
editable attribute for transport node are increase in
length, unification of transport node and decrease the
velocity in transport node. The editable input factor for
buffer node is as follows: Decrease the number of
connected transport node, decrease the number of
connectedsourcenode,andincreasethecreationtimeof
for buffer node are increase the number of connected
work node, increase the processing time and set up time
Increasethenumberofconnectedsourcenode,decrease
addition of work node and decrease the processing time
editable output factor is decrease the number in
decrease the number in connected buffer node. The
editable attribute for transport node are increase of
46
in connected work node. Figure 9 shows editable layout

forcase4.
Decreasethenumberofconnectedsourcenode,increase
decrease of work node and increase the processing time
editable output factor is increase the number in
increase the number in connected buffer node. The
editable attribute for transport node are decrease of
length,parallelprocessingoftransportnode,andincrease
the velocity in transport node. The editable input factor
for buffer node is as follows: Increase the number of
connected transport node, increase the number of
connectedsourcenode,anddecreasethecreationtimeof
for buffer node decrease the number of connected work
node,anddecreasetheprocessingtimeandsetuptimein
connectedworknode.
Fig.10Layouteditor
IMPLEMENTATION
WehaveimplementedlayouteditorusingMicrosoftVisual
Studio 2010 MFC. The layout editor makes modeling and
simulation for initial layout. Layout editor can be
recommendedtheeditablelayoutbyeachcase.Figure10
describes layout editor. Users are able to initial layout
modeling and simulation. Figure 11 shows the result of
initial layout model and simulation. Moreover, users can
select an option according to each case considering
simulation results. Figure 12 shows the selection of
editable layout. If users select the option, layout is
automatically remodeled. Figure 13 shows the result of
editedmodelandsimulation.
Fig.11Theresultofinitiallayoutmodelandsimulation
Fig.12Selectionofeditablelayout
CONCLUSIONS
This paper proposes simulation based layout design
method.Inordertodescribetheproposedmethodology,
this paper presents layout design process and layout
editor. Nodes of buffer and transport are set infinite
capacity. The result from the simulation of layout is
classified as four types along the states of buffer and
transport nodes. This paper introduces recommendable
layout to respond each situation of four types. If users
select the option, layout is automatically remodeled. The
proposedmethodforeditablelayoutdesigninthispaper
allows layout designer to swiftly generate assembly lines
withconsiderationofkeyfactors.Thisadvantageprovides
rapid and reasonable design and modification for layout
using the result from the simulation that represents
unexpected situation at the initial status. For the
implementationoftheproposedlayouteditor,thispaper
employs Discrete Event Systems Specifications (DEVS)
formalism. The layout editor can make model and
simulationforinitiallayout.Thisistherecommendedthe
editablelayoutbyeachcase.
Fig.13Theresultofeditedmodelandsimulation
47
[9] SuYoung KimJungTae ParkSeongWoo Choi,

Digital factory Application for layout design &
material handling system : Applied Case to BLU
Manufacturing, Productivity Review, Vol.25, No.1,
March.2011
[10] YoungJinKim,SangDoNoh,JoungH.MunOptimal
bufferallocationofthesolenoidproductionlineusing
simulation, Korean Simulation Association, 17 (4),
pp.5160,2008.12
[11] Youngjin Park, Hyunshik Shin, Kyung Hoon Chung,
Sung Won Hong, Sang Do Noh, Material Flows
Analysis and Storage Plans Evaluations by Virtual
Automotive Body Shop, Proceeding of the KAMES
2002JointSymposium
[12] Chu Shik Jhon, Jae Hwang Lee, Kyoung Son Jhang,
KangLee,SungTaeJung,Thepartialimplementation
of a blockbased layout generator and the basic
researchonlayoutcompactionsystems.,NationalIT
IndustryPromotionAgency,1990
[13] Chris J. J. Lu, K. H. Tsai, Jackson C. S. Yang and Yu
MichaelWang,OptimalLayoutDesignofAutomated
Systems Using Topology Connectivity Method,
Proceedings of the 1996 IEEE International
Conference on Robotics and Automation
Minneapolis,MinnesotaApril1996
[14] HongSeokPark,YongQiangWang,HungWonChoi,
Jin Woo Park, Sang Yeong Jeong, Ontologybased
Assembly Sequence Planning and Automatic
Generation of Feasible Assembly Sequence, 2010,
TheKoreanSocietyofMechanicalEngineer,2010
[15] Zeigler, B. P. (1976). Theory of modeling and
simulation.WileyInterScience.
[16] Zeigler, B. P. (1990). Objectoriented simulation with
hierarchical.Modularmodels.AcademicPress.
[17] Tag Gon Kim, DEVSIM++ v3.0 Users Manual,
Department of Electrical Engineering, KAIST, Korea,
2009.
ACKNOWLEDGMENT
This work was partially supported by the Defense
Acquisition Program Administration (UD100009DD), the
Agency for Defense Development (UD080042AD) and
KoreaResearchFoundation(20100021040)
REFERENCES
[1] Mansoo Han and DongJo Park, Optimal buffer
allocation of serial production lines with quality
inspection machines. Computers & Industrial
Engineering,Vol.42pp7589,2002
[2] M.IqbalandM.S.J.Hashmi,Designandanalysisofa
virtualfactorylayout,JournalofMaterialProcessing
Technology118(2001)403410
[3] Layek AbdelMalek and Chi Tang, An integrated
approachtothelayoutofflexibletransferlines(FTLs):
Buffer Stocks Allocation, International Journal of
Production Economics, Vol. 30, No. 31, pp. 489499,
1993
[4] P. Klingstam, P. Gullander, Overview of simulation
tools for computeraided production engineering,
ComputersinIndustry38(1999)173186.
[5] A.M.A. AlAhmari, K. Ridgway, An integrated
modeling method to support manufacturing system
analysisanddesign,ComputersinIndustry38(1999)
225238.
[6] Saifallah Benjafaar, Sunderesh S and Shahrukh A.
Irani, Next Generation Factory Layouts:Research
challenges and recent progress, INFORMS, Vol. 32,
No.6,pp5876,2002
[7] Yoram Koren and Moshe Shpitalni, Design of
reconfigurable manufacturing system, Journal of
manufacturingsystemsVol.29,pp130141,2010
[8] Abdelghani Souilah, Theory and Methodology
Simulated annealing for manufacturing systems
layout design, European Journal of Operational
Research82(1995)592614
48

TheProceedings
Elasto-Plastic Stress Analysis of Steel Fibre Reinforced Aluminum

Metal Matrix Composite Plates
AlperAtmaca1OsmanSelimTrkba2MuhammedEminErdin3HalilAykul4
1
MachinesTechnicalProgram,HititUniversity,Hititni.MeslekYksekokuluSamsunCad.No:9919169orum,Trkiye,alperatmaca@hitit.edu.tr
MechanicalEngineeringDepartment,GaziUniversity,Gazini.MhendislikFakltesiYkseliSok.No:5Maltepe/Ankara,Trkiye,turkbas@gazi.edu.tr
MechanicalEngineeringDepartment,HititUniversity,Hititni.MhendislikFakltesievreYoluBulvarNo:819030orum,Trkiye,eminerdin@hitit.edu.tr
4
MechanicalEngineeringDepartment,HititUniversity,Hititni.MhendislikFakltesievreYoluBulvarNo:819030orum,Trkiye,halilaykul@hitit.edu.tr
2
3
ARTICLEINFO:
Received:2November2012/Revised:8November2012/Accepted:13November2012
Abstract:
CompositePlates
AluminumMatrix
SteelFibreReinforcement
ElastoplasticStress
FiniteElementAnalysis
Background: obtaining displacements and stresses in composites is presented.

Experimentalmethodsareusedforobtainingmechanicalpropertiesofcompositestructure
Methods:
andfiniteelementmethodisusedforelastoplasticstressanalysis.
Stressdistributionsfordifferentorientationanglesarecalculatedusingfiniteelement
Results:
analysis.
Manufacturingtechniquesarecompared.Minimalstressesandyieldingregionsare
Conclusions:
specified.
Previous studies about stress analysis of composite plates are examined. A numerical method for
Citation:AtmacaA.,etal.:ElastoplasticStressAnalysisofSteelFibreReinforcedAluminumMetalMatrixCompositePlates,2ndInternationalConferenceManufacturingEngineering&
Management2012,(2012),p.4952,ISBN 9788055312163
INTRODUCTION
material is manufactured using two different methods
which are hot pressing method and resiny method.
Composite plate properties and quality differences are
correspondedintermsofmanufacturingmethod.
This study is constituted from three stages. First of all,
ametal matrix composite plate is obtained. Matrix
materialofthecompositestructureisaluminumplateand
reinforcement material is steel fibre. Steel fibres are
placed on the matrix in only one axis. To procure abond
between matrix and fibre hot pressing or epoxy resin is
used.Compositestructureissubjectedtoheattreatment
for an hour in 80 oC for gelling and hardening of epoxy
resin. Resiny manufacturing method is simpler than hot
pressingmethod.Inthismethod,highaffinityofaluminum
to oxygen does not engender a disadvantage. After the
manufacturing of composite plate, simple tensile and
shear tests are performed to achieve engineering
constants and mechanical properties of the composite
structure. It is seen that, tensile strength of composite
materialincreaseswiththeincreasingfibreratio.Fromthe
performed mechanical tests, it is understood that has no
contribution on the strength ofcomposite material but it
is avery good adhesive indeed. In the final stage, elasto
plastic finite element based stress analyses are executed
using ANSYS computer packaged software. In the finite
element analyses, elastoplastic stress values are
calculated for (0/90o)2 symmetrical cross reinforced and
(15/15o)2, (30/30o)2, (45/45o)2 symmetrical angular
reinforced laminated aluminum metal matrix composite
plates. In symmetrical laminated plates, plate is simply
supportedfromallofthesidestopreventthemtomovein
xandydirections.TsaiHillTheoryisusedasyieldcriteria
intheanalyses.
Development of technology gained a great acceleration

during the last century. Materials that are procured from
naturecannotkeepupwiththisdevelopment.Thus,new
searching about materials became compulsory. To meet
the material requirements of developing technology, a
combined structure is developed which is formed by
joiningtwoormoredifferentmaterialsinmacrolevel.This
new structure which is called composite material has the
superior properties of the materials which form itself.
Types and usage areas of composite materials are
increasingdaybyday.
Composite plates with aluminum metal matrix show
elastoplastic behavior during forming operations. 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.
Initiationofplasticdeformationinacompositematerialis
determined by the help of a yield criterion. Residual
stressesoccurinthematerialbecauseofthedeformations
arisingfromplasticstresses[1,2].
Daining et al. investigated the elastoplastic stressstrain
behaviorsofmetalmatrixcompositematerialsusingfinite
element method [3]. Sayman investigated the elasto
plastic behavior of simply supported stainless steel
reinforced aluminum metal matrix laminated composite
plates under transverse [4] and inplane [5] loads using
finite element technique. Sayman stated that composite
structure increases yield strength and rigidity. Also it is
stated that residual stresses can be used for enhancing
mechanicalproperties.zbenandArslaninvestigatedthe
elasticandplasticbehavioroflaminatedcompositeplates
undertransverseloadsusingfiniteelementmethod[6,7].
Purpose of this study is to determine plastic behavior of
composite materials. To find the plastic behavior manner
of the material, finite element based elastoplastic stress
analysis is executed using ANSYS packaged computer
software. Composite material is manufactured. Tensile
and shear tests are carried out to obtain necessary data
for elastoplastic stress analysis. Besides, composite
COMPOSITESTRUCTURE
Two 5083 series aluminum plates are prepared in the
dimensions of standard tensile test sample. Chemical
composition and mechanical properties of aluminum is
giveninTable1andTable2respectively.
49
A. Atmaca, et al.
Elasto-plastic Stress Analysis of Steel Fibre Reinforced Aluminum Metal Matrix Composite Plates
Tab.1Chemicalcompositionof5083seriesaluminum
Element
%Mass
Element
%Mass
Cu
<0.10
Zn
<0.20
Mg
4.65
Ni
<0.05
Mn
0.74
Cr
0.08
Fe
0.18
Ti
<0.10
Thickness of the obtained composite structure is more

than 3 mm. Thus, the gauge length is calculated with
belowequation;
Lo=5.65(So)1/2
where Lo is initial gauge lengthof the sample, So is initial

crosssectional area and 5.65 is acoefficient related with
thethicknessofthetensilesample.Aspecialapparatusis
used in tests for preventing shear between matrix and
fibres.Asnapshotfromthesheartestingoperationisseen
in Figure 2 and graphical output of the tensile testing is
seeninFigure3.
Si
0.08
Tab.2Mechanicalpropertiesof5083seriesaluminum
Property
X[MPa]
Y[MPa]
E[GPa]
Value
104
104
70
Property
G[GPa]
5 [%]
[kg/dm3]
Value
26
30~38
2.7
PaksoyresinispreparedbymixingcomponentsAandBin
acontainer for approximately 3 minutes and applied on
the aluminum plate. Resin composition and properties is
giveninTable3.
Tab.3Epoxyresincompositionandproperties
ComponentNumber
2(A&B)
MassiveMixtureRatio(A/B)
50/50
VolumetricMixtureRatio(A/B)
50/50
MixtureDensity[gr/cm3],at20oC
1.5
MixtureLife[min.],200gr.at20oC
60~100
OverallHardeningTime[week],at23oC
1
Steel fibres of 150 mm length are placed on resiny

aluminumplates.Mechanicalpropertiesofsteelfibreare
giveninTable4.
Tab.4Mechanicalpropertiesofsteelfibre
Property
Value
X
[MPa]
675
Y
[MPa]
675
E
[GPa]
200
Fig.2Asnapshotfromsheartestingoperation
[kg/dm3]
7
Some more resin is applied on steel fibres and the other

aluminum plate is placed on them. Plates are slightly
compressed by hand to avoid pores on structure. After
heattreatmentasmentionedabove,resinishardenedand
bond is procured between aluminum matrix and steel
fibres.Amanufacturedsampleofcompositeplateisseen
inFigure1.
EXPERIMENTALSTUDY
Tensile and shear tests of composite structure is
performedforfindingnecessarymechanicalpropertiesof
compositematerialforelastoplasticstressanalysis.Tests
are performed in Hitit University Engineering Faculty
Laboratories with 100 kN computer controlled Shimadzu
Autograph Universal Testing Machine. The samples for
tensiletestsarepreparedaccordingtoTS138EN100021
standards.
Fig.3Graphicaloutputofthetensiletesting
Necessary mechanical properties of composite material
for elastoplastic stress analysis are obtained from the
resultsoftensiletestsasgiveninTable5.
Tab.5Mechanicalpropertiesofcompositematerial
Property
X[MPa]
Y[MPa]
S[MPa]
Value
130
104
49
Property
k[MPa]
n[]
12[]
Value
2570
0.62
0.33
Property
G12 [GPa]
E1[GPa]
E2[GPa]
Value
41
110
87
ELASTOPLASTICSTRESSANALYSIS
Elastoplastic stress analyses are executed in Hitit
University Engineering Faculty using ANSYS packaged
software. Afour laminated plate of 50x50x3.2 mm
dimensionsismodeledinwhichthicknessofeachplateis
0.8mm.themodelissimplysupportedtopreventmotion
Fig.1Asampleofmanufacturedcompositeplate
50
inxandyaxes.Themodelissubjectedtoapressureof10
MPaasshowninFigure4.
A. Atmaca, et al.
where is the yield strength of the material, Kis the

strength coefficient and n is the strain hardening
exponent.
Stress distribution on finite element composite model is
seeninFigure5.
Fig.4 Finite element model of the elastoplastic stress

analysisproblem
The solution procedure for above mentioned mechanical
problem will be described step by step thereinafter. The
model is divided into elements of finite number. Direct
StiffnessMatrix(D)ofallelementsandthewholemodelis
found.
1
0
1
0

1
1
0 0
2
In this equation, E; is the elasticity modulus and ; is the

Poissonsratio.StressDisplacementMatrix(B)isfoundfor
allelements.
0
0
0
1
0
0
0

det
Fig.5Stressdistributiononfiniteelementmodel
Stress variation from the side of composite plate to the

centerisseeninFigure6.
Inthisequation,superscripteindicateselementand
det =
whereJistheJacobeanMatrix.

RigidityMatrixisfoundforallelements.
Fig.6Stressvariationoncompositeplate
.
. .
Then Overall Rigidity Matrix is constituted by combining

Element Rigidity Matrices. Displacements are calculated
fromtheequation
F=k.q
where F indicates forces in nodal points. Finally, stress

valuesarecalculatedfromtheequation
=D.B.q
In this equation, stress matrix () is obtained in the form

of
. These stresses are replaced in the
TsaiHillequivalentstressequationwhichisgivenbelow.

RESULTS&CONCLUSION
Elastoplastic stress analyses results for all symmetry and
orientation situations in critical nodes (A, B, C, D and E
whichareseeninFigure5)aregiveninTable6.
Tab.6Resultsoftheelastoplasticstressanalyses
If the equivalent stress is less than the yield strength (X),

elasticity limit is not exceeded and plastic analysis is not
necessary. If the equivalent stress is more than the yield
strength(X),stressesarecalculatedfromLudwigEquation
whichisgivenbelow.

.
51
A. Atmaca, et al.
Conclusionsfromtheperformedanalysesarelistedbelow:
Resinhasnoeffectonstrengthofthecomposite
structure.
Densityofresinislowandhasnonegativeeffect
onweightofthecompositestructure.
In resiny method fibres do not penetrate into

matrix, thus thickness is more in resiny method
thanhotpressingmethod.
Resiny method is simpler and cheaper than hot

pressingmethod.
In hot pressing method, structures of fibre and

matrix materials change and their strength
valuesdecreasebecauseofhightemperatures.
In hot pressing method, oxidation is an

importantproblem.
In resiny method, temperature strength is

limited by the decomposition temperature of
the resin which is 250 oC for the Paksoy resin
usedinthisstudy.
In symmetrical orientation, maximal stress

occurred in (0/90o)2 reinforcement angle and
minimal stress occurred in (0/15o)2
reinforcementangle.
In antisymmetric orientation, maximal stress

occurred in (15/15o)2 reinforcement angle and
minimal stress occurred in (0/90o)2
reinforcementangle.
In antisymmetric orientation, minimal plastic

region occurred in (15/15o)2 reinforcement
angle.
In symmetrical orientation, minimal plastic

o
regionoccurredin(0/15 )2reinforcementangle.
In symmetrical orientation, yielding occurred

onlyinthecentralregion
In antisymmetric orientation, yielding occurred

incentralregionandcorners.
REFERENCES
[1] Mendelson, A., Plasticity Theory and Application,
TheMacmillanCompany,NewYork,349(1968).
[2] Owen, D.R.J., Hinton, E., Finite Elements in
Plasticity, Pineridge Press Limited, Swansea, U.K.,
593(1980).
[3] Daining, F., Hang, Q., Shangdong, T., Elastic and
Plastic Properties of MetalMatrix Composites:
Geometrical Effects of Particles, Computational
MaterialsScience,6,303309(1996).
[4] Sayman,O.,ElastoplasticStressAnalysisinStainless
Steel Fiber Reinforced Aluminium Metal Matrix
Laminated Plates Loaded Transversely, Composite
Structures,43,147154(1998).
[5] Sayman, O., Akbulut, H., Meri, C., Elastoplastic
StressAnalysisofAluminiumMetalMatrixComposite
Laminated Plates under Inplane Loading,
Computers&Structures,75(1),5563(2000).
[6] zben, T., Arslan, N., Expansion of plastic zone and
residual stresses in the thermoplasticmatrix
laminated plates ([0/]2) with a rectangular hole
subjected to transverse uniformly distributed load
expansion,ComputationalMaterialsScience,44(3),
895912(2009).
[7] zben, T., Arslan, N., FEM Analysis Laminated
Composite Plate with Rectangular Hole and Various
Elastic Modulus under Transverse Loads, Applied
MathematicalModeling,34(7),17461762(2010).
52

TheProceedings
Experimental and Numerical Analysis Of Foldable Plastic Packaging

Buckling Failure
SevketCelovic1TaskoManeski2TomazVuherer3MilosTipsarevic4MiloradZrilic5
1
PhDstudentFacultyofMechanicalEngineeringBelgrade
FacultyofMechanicalEngineeringBelgrade
FacultyofMechanicalEngineeringMaribor,Slovenia
4
Danfoss,Denmark
5
FacultyofTechnologyandMetallurgyBelgrade
2
3
ARTICLEINFO:
Category:PreliminaryCommunication
Abstract:
FEM
Buckling
Numerical
Experimental
FoldablePlasticPackaging
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. Numerical analysis was conducted by the
application of finite elements using KOMIPS software. The experiments were executed with the equipment GOM
and software application ARAMIS. 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. This article will show how we can
predict experimental results by the means of finite element analysis; we find this is a very strong learning tool that
would enable designers to improve the structural strength of new products in future. Experimental and numerical
analysis results to date have shown high degree of correlation.
Citation:CelovicS,etal.: ExperimentalandNumericalAnalysisOfFoldablePlasticPackagingBucklingFailure,2ndInternationalConferenceManufacturingEngineering&Management
2012,(2012),p.5355,ISBN 9788055312163
INTRODUCTION
Numerical analysis was conducted by the application of
finite elements using KOMIPS software [1,4]. The
fundamental of analysis is related to the mechanism of
failureoffoldablepackaging.Wewantedtopointoutthe
advantagesofapplyingmodernoptical3Dmeasuruentof
deformationsinidentifyingbucklingeffectsgenerateddue
to compressive loads. The equipent typically consited of
two mobile optical digital stereo cameras supported by
ARAMIS software applications [3]. 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.
ARAMIS can analyse, calculate and report the
deformationofpartsofthestructureorentirestructure.
Here are the fields of application of such measurement
equipment:
3Ddeformation,movementandvibrationdetection
Measuringofdynamicbehaviorforupto25Hz
Linear and nonlinear behavior of viscouselastic
materials
Testing of homogeneous, nonhomogeneous,
isotropicandanisotropicmaterials
Creep testing and ageing effects of complex
structures
NVH testing in car industry and also in an
aerodynamictunnel
Calculation, visualization and display of the position
ofmeasurementpointsindifferentphasesoftest
VerificationoftheFEresults
Fig.1Numericalmodel
ModulusofelasticitywasE=1200MPa.Totalcompressive
load pointing downwards, equally distributed along the
side, was 4023 N (400 kg). This equated to 1341 kg of
linear force acting upon entire length of the top face of
the crate. Long side compression strength are presented
onthefigure2and3.
NUMERICAL FEM ANALYSIS OF PLASTIC FOLDABLE

PACKAGINGINBUCKLING
Long side FE models include the bottom face simply
supported (surface support) and load continually applied
toeachnodeofthetopfacepointingdownwards(Figure
1)[1,4].
53
S. Celovic et al.
Experimental and Numerical Analysis Of Foldable Plastic Packaging Buckling Failure
Maximumtotalspatialdeformationwas3.7mm.Vertical
deformationoftopedgewas1mm.
Lateraldeformationinhorisontalplaneofthetopedge
middlepointwas0.92mm.
Thirdmode.Naturalfrequency;65.9Hz.
Maximumhorisontallateraldeformationofthetopedge
middlepointis6.5mm
Fig.4Firstthreemodesoscilations
Bucklingforceestimatebasedonstaticanddynamic
analysisare:
Staticcalculation:linearelasticlimittostressis27
MPa/5.4MPa=5.
Dynamiccalculation:amplitudeinthefirstmodeto
deformationduetostaticforceis3.3mm/0.92mm
=3.59.
As3,59<5weconcludethatbucklingwouldpreceedethe
plastic deformation. Estimated buckling force would be
Fbuck = 67050 N 3.59 / 5 = 48142 N. (4.8 tonnes). This
determined the load carrying capacity of the crate in
compression.Theshownanalysisofthebucklingforceand
the load carrying capacity was not a finction of the
modulusofelasticity.
Fig.2 Deformation of long side Von Misses Stress [MPa]

(Max5.41MPa)
EXPERIMENTAL ANALYSIS OF PLASTIC FOLDABLE

PACKAGINGINBUCKLING
Fig.3Stressfieldoflongside
The based of buckling analysis for the long side are
calculatednaturalfrequencyandmainmodeoscilation.
Natural frequences and the modes shapes for first three
modesareshownonthefigure4.
Experimental verification [2] of the previous numerical

analysis was executed with the described equipment for
3D optical deformation measurements on the Instron
testing machine. Results are shown on the following
picture. The measured vertical deformation was 1.7 mm
(figure5).
Firstmode.Naturalfrequency:32.4hz.
middlepointis3.3mm
Fig.5Experimentalverification
Next example are buckling effects which appeared much

beforetheplasticdeformationwithexperimentalanalysis
(figure 6). Buckling was determined by the means of 3D
opticalmeasurementequipment.
Secondmode.Naturalfrequency:61.7Hz.
middlepointis6.3mm
54
Experimental and Numerical Analysis Of Foldable Plastic Packaging Buckling Failure
S. Celovic et al.
Fig.6Experimentalbucklinganalysis
CONCLUSIONS
Themethodologydescribedhereshowedsatisfyingresults
regarding the buckling effects on plastic packaging. We
gainedconclusionsabouttherootcausesofthebuckling.
Theanalysiswasconsistentwithallpreviously conducted
observations of container behaviour due to compressive
loads. The difference is that the previous conventional
observations of deformations could only detect the
consequenceofbuckling(structuralfailure)wherethe3D
opticalequipmentenabledustoalsounderstandtheroot
cause.Thistypeofanalysisisapplicabletoawiderangeof
structuralproblemswithdiverseloadingpatterns.
REFERENCES
[1] Maneski, T., Computer modeling and structure,
Monografy, Faculty of Mechanical Engeneering,
Belgrade(1998)
[2] Maneski T., Nestorovic B., Validation numerical
modeling with 3d optical measurement of
deformations of foldable plastic packaging buckling
failure,SAJ_2011_3,UDK621.798.1:678.5
[3] SoftwareARAMIS,GOM,Germany
[4] SoftwareKOMIPS,FacultyofMechanicalEngineering
55

TheProceedings
The Impact of Human Resources Management on the Performance

of Small and Medium Enterprises in Albania
FrederikCucllari1MirelaCini2AidaGabeta3
1
FanS.NoliUniversity,ShetitoreRilindasit,7001Korce,Albania,Email:fcucllari@ymail.com
FanS.NoliUniversity,ShetitoreRilindasit,7001Korce,Albania,Email:mirelacini@yahoo.com
FanS.NoliUniversity,ShetitoreRilindasit,7001Korce,Albania,Email:gabetaaida@yahoo.com
2
3
ARTICLEINFO:
Category:Shortcommunication
Abstract:
Small and medium enterprises (SMEs) continue to be the backbone of the EU economy. SMEs represent 99.9 per
cent of the total number of active enterprises in Albania. This paper was aimed at highlighting the importance of
human resources management on the performance of the SMEs sector, by evoking the experiences and challenges
of business environment in Albania, which is mainly based on SMEs. 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,
but is the condition to succeed.
Citation:CucllariF,etal.:TheimpactofhumanresourcesmanagementontheperformanceofsmallandmediumenterprisesinAlbania,2ndInternationalConferenceManufacturing
Albania
Humanresourcesmanagement
Smallandmediumenterprises
INTRODUCTION
enterprises. About 50 per cent enterprises are located in
regionsofTiranaandDurres.Otherregionswithastrong
presenceofSMEsaretheregionsofFier,VloraandKorce.
Thelowestpercentagesofbusinessesareintheregionsof
Kukes(0.9percent),Diber(2percent)andLezhe(2.8per
cent). (Fig. 1). 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.
SMEs representa crucial sector of the Albanianeconomy

because they provide a significant contribution to
economic growth, employment creation, poverty
reduction and social development. This is demonstrated
bythefactthatSMEsrepresent99.9percentofthetotal
numberofactiveenterprisesinAlbania[5].Theaimofthis
paper is to discuss the importance of human resources
management on the performance of the SMEs sector in
Albania.
The analysis is based on statistics come mainly from
InstituteofStatistics(INSTAT),nationalsurveysonSMEsin
Albania, European Commission and some empirical
studies.
Thepaperisorganizedasfollowing:Section2providesan
overview of the Albanian SMEs and its role in national
economy.Insection3highlightstherelationshipbetween
the performance of SMEs and human resources
management. Finally, this paper will end up with the
conclusion.
SMESANDITSROLEINALBANIANSECONOMY
AlbaniasSMEpolicyisbasedontheEuropeanCharterfor
Small Enterprises and the country is committed to
implementingtheSmallBusinessActforEurope.Albanias
definition of SME is in line with the EUs as regards the
number of employees and autonomous partners and
linked enterprise concepts. The small business sector is
well represented in Albania and is similar in structure to
theEUs[4].InAlbania,SMEsrepresent99.9percentofall
activeenterprisesand73%ofGDP.TheSMEscontribution
in employment is around 66.9 per cent [5]. Based on
INSTAT (2011) data, the number of active businesses till
theend2010reached100,687whichshowagrowthof1
per cent comparing to 2008. The birth rate of new
enterprises for 2010 is 16 per cent higher compared to
2009.About92 percentoftotalenterprisesarewith14
employed (services and trades sectors are dominated by
microenterprises).Themostpart,62percent,haveonly
selfemployer. The SMEs activities in Albania are focused
inthelocalmarket.
Intermsofgeographicallocationofenterprises,theregion
of TiranaDurres has a higher concentration of private
Fig.1TerritorialdistributionofSMEsandemployment[9].
Insectoralterms75percentareintradeandservices.The
sectorsoftradeandservicesprovide42.5percentofthe
privatesectoremployment.(Fig.2).
Fig.2DistributionofSMEsbysectorofindustry[10].
Against this background, the factors influencing the level
of development of the SMEs sector in Albania are the
following:
Financingschemes;
Innovation;
Humanresourcedevelopment.
56
The Impact of Human Resources Management on the Performance of Small and Medium Enterprises in Albania
F. Cucllari, et al.
Tab.2 Linking human resources management and

performance[3]
THE RELATIONSHIP BETWEEN THE PERFORMANCE

OF SMES AND THE HUMAN RESOURCES
MANAGEMENT.
Human resources management covers a wide range of
activities. Delery and Shaw [2], argued there is a general
agreement that (1) human capital can be a source of
competitive advantage, (2) that human resources
management practices have the most direct influence on
the human capital of a firm, and (3) that the complex
nature of human resources management systems of
practice can enhance the inimitability of the system. The
impact of human resource management on performance
has become the dominant research issue in this field [6].
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. Although past research findings are
generally positive, there is still some uncertainty about
how certain types of human resources management
practices influence business performance outcomes. The
table (Tab. 1) below shows best practices human
resources [12]. Pfeffer [11] listed seven human resources
practices: employment security; selective hiring, self
managed teams, high compensation contingent on
performance, training, reduction of status differentials,
andsharinginformation.
Human
resources
management
practices
Human
resources
management
outcomes
Selection
Commitment
Training
Appraisal
Quality
Rewards
Jobdesign
Flexibility
Involvement
Statusand
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. The results of the training and development
surveymadeintheyear2010[1]showaconcernlimited
to the Albanian SME sector for the development of
training activities. The results of this study show that
incidence of training increase with size of business: while
fewertenpercentofthesmallestbusinessesprovidedany
type of training. (Fig. 3). The most important reason for
trainingemployeesappearstoberelatedtoprovidingjob
performance. The survey findings indicate that most
enterprisesregardhumanresourcedevelopmentasahigh
priority, in terms of its potential impact on business
performance,butrelativelyfewprovidedtraining.
Tab.1Bestpracticesinhumanresources[12]
There are several lists for high performance work

practices, or best practice human resources, each with
varying content and with different ways of
operationalisingtheindividualhumanresourcesactivities.
Butattheirheart,moststudiesemphasiseenhancingthe
skill base of employees through selective staffing,
comprehensivetrainingandbroaddevelopmentalactivity,
aswellasencouragingemployeesthroughempowerment,
participative problem solving and teamwork and group
based incentives. Appropriate human resources
managementpracticescanimproveemployeemotivation
and identification with the employer company, and,
therefore,theirwillingnesstolearnandtousewhatthey
learned in their work [3]. Table 2 illustrates how human
resources management practices can influence the
behaviour of workers and, indirectly, company
performance. The performance of SMEs in Albania is
quantified according to criteria of appreciations of the
employees by the entrepreneurs, in conjunction with
organizational performance objectives. Generalizations in
Albanian SMEs are difficult because of the different
characteristics in the size, businesses structures,
production,lifecyclesstagesandownership.
Fig.3 Types of training provided, by size of the

enterprise[1].
The understanding of the value of enterprises human
resource is less developed among Albanian enterprises.
Thecentralizationofpoweranddecisionstoonepersonor
small management group is an indication of a less
developmenthumanresourcemanagementsystem,which
in turn acts as a constraint that negatively affects the
overall performance of the enterprise and slows down
growth.Knowledge,skills,empowerment,delegationwith
confidence, setting goals for others, employee appraisal,
motivation, coaching people and team management are
some of the key topics that will create a positive human
resource management system within the enterprises,
allowing for a higher degree of innovation and
productivityenhancements.
CONCLUSION
Tofurthersupportandpromoteeconomicgrowth.Albania
took a series of measures to support private sector and
foster business startups. It signed the European Charter
for Small Enterprises, and its policies are guided by
Europeanstandardsandpractices.Priorityhasbeengiven
57
F. Cucllari, et al.
The Impact of Human Resources Management on the Performance of Small and Medium Enterprises in Albania
sized enterprises in the EU, 2011/12, Rotterdam,

September2012.
[5] EuropeanCommission,2012.SBAFactSheet2012
Albania,
available
at,
http://ec.europa.eu/enterprise/policies/sme/facts
figuresanalysis/performancereview/files/countries
sheets/2012/albania_en.pdfand
[6] Guest, D. E., 1997. Human Resource management
and performance: a review and research agenda,
The International Journal of Human Resource
Management,Vol.8,Issue3,p.263276.
[7] INSTAT, 2010. Albania in figures 2010, INSTAT,
Tirane.http://www.instat.gov.al
[8] INSTAT, 2011:1, Structural survey of enterprises,
INSTAT,Tirane.http://www.instat.gov.al
[9] METE,2011.AnnualStatisticalBulletin2010,Tirane,
availableat,http://www.mete.gov.al
[10] METE, 2011. Strategic programme for innovation
and technology development of the SMEs for the
period 20112016, METE, Tirane, available at,
http://www.mete.gov.al
[11] Pfeffer, J., 1998. The human equation: building
profitsbyputtingpeoplefirst,Boston:HBSPress.
[12] Youndt,M.A.,Snell,S.A.,Dean,J.W.andLepak,D.P.,
1996.Humanresourcemanagement,manufacturing
strategy and firm performance, Academy of
ManagementJournal,39,p.836866.
to the development of small and medium businesses,

mainly by supporting the development of extraction and
processingindustriesandnonfoodindustries,andrelying
onamorerationaluseoflocalresources.Amajorrolein
development of SMEs rests with the human resources
management. Human resources practices complement
pathways by which performance analyzed in terms of
knowledge, skills, behaviours and outcomes can be
measured in economic and social. The most Albanian
enterprisesregardhumanresourcedevelopmentasahigh
priority, in terms of its potential impact on business
performance,butrelativelyfewprovidedtraining.
REFERENCES
[1]
[2]
[3]
[4]
Cini,M.,Cucllari,F.andGabeta,A.,2011.Trendsand
future prospects of training and development in
Albania, Transformations in Business & Economics,
Vol.10,No.2(23),p.137150.
Delery, J.E. and J.D. Shaw, 2001. The strategic
management of people in work organizations:
review,synthesis,andextension,paperpresentedat
the Academy of Management Meeting 2001 in
WashingtonD.C.
EuropeanCentrefortheDevelopmentofVocational
Training (CEDEFOP), 2011. Research paper No. 19.
The impact of vocational education and training on
companyperformance,Luxembourg,2011.
European Commission, 2012. EU SMEs in 2012: at
thecrossroads.Annualreportonsmallandmedium
58

TheProceedings
Jet Tab and Dome Deflector TVC in Solid Rocket Motor

Mathematical Model and Test Comparison
NikolaDavidovi1PredragMilo2BranislavJoji3oreBlagojevi4MarkoMilo5
1
PhDMechanicalEngineering,ResearchEngineer,EDePro,Belgrade,Serbia,email:nikola.davidovic@edepro.com
PhDMechanicalEngineering,ResearchEngineer,EDePro,Belgrade,Serbia,emai:milos.predrag@edepro.com
PhDMechanicalEngineering,Professor,FacultyforMechanicalEngineringUniversityofBelgrade,Serbia
4
5
PhDMechanicalEngineering,AssociateProfessor,UniversityofBelgrade,FacultyofMechanicalEngineering,Serbia
2
3
ARTICLEINFO:
Category:TechnicalNote
Abstract:
Thrustvectorcontrol
Nozzle
Jettab
Domedeflector
Test
Research and accompanying mathematical model were realized within the national program for the low cost cosmic
transportation systems development. Jet tab and dome deflector thrust vector control (TVC) systems were chosen
to be the object of the research, because of their simplicity, comparing to other TVC systems. Mathematical model
was built on the fundamental test data and compared to the real rocket motor test data. Derived method of TVC
performance prediction is in alignment with the measured values and presents a reliable engineering tool, since it
depends on engineering design and control parameters.
nd
Citation:DavidoviN.,etal.:JetTabandDomeDeflectorTVCinSolidRocket MotorMathematicalModelandTestComparison,2 InternationalConferenceManufacturingEngineering&

Management2012,(2012),p.5963,ISBN9788055312163
NOMENCLATURE
A
Cf
F
Fo
h
K
Ls
M
P
Po
rc
Xiz
d
1
a
b
c
cr
e
of
ob
r
x
y
z
Area(m2)
thrustcoeficient
force(N)
thrustwithoutTVC(N)
obstacleheight(m)
ratioofthrustsidetolossforce
positionofshockwavemeasuredfromexit(m)
Machnumber
pressure(Pa)
totalpressurebeforeshockwave(Pa)
nozlleradius(m)
nozzlewalllengthfromthroattoexit(m)
nozlledivergenceangle(rad)
obstaclenozzleangle(rad)
thrustvectorangle(rad)
obstaclerelativegap
parametersjustbeforetheshockwave
areaindisturbedregioninnozzle,axial
blocked
areainnondisturbedregioninnozzle
critical
exit
obstaclefront
obstacleback
relative
axialdirection
lateraldirection
relativeblocked
whateverisbeingdone,itisproportionaltoblockedarea.
All of this contributed to the efficiency of control
engineers.Jet tab and dome deflector TVC are the
members of mechanical systems with fixed nozzles.
Mechanical systems are based on different mechanical
obstacles,whichareusedtomodifyflowaroundobstacle
and/or in the nozzle and consequently changing pressure
distribution. Several mechanical TVC systems have been
developed since: jet vane, internal maneuvering vanes,
jetavator, axial jet deflector, jet tab (spoiler), domed
deflector and domed segmented deflector, Fig.1. The jet
tabsysteminvolvesaplate,attheendofthenozzlethat
can be rotated in and out of the nozzle, disrupting the
flow.Initialadvantagesofthrustdeflection,suchasbeing
proportional to the tab area exposed to the flow, makes
systems control relatively easy. The downside of this
systemisthat,whenthetabisinthefluidstream,theflow
stalls on the tab. The stalled flow causes severe erosion
inside the nozzle and also additional losses.Dome
deflectorissimilartoajettab,inoperatingprinciple,but
its geometry is 3dimensional, which causes not only
nozzlewalls,butalsodomeitself,tocreatesideforce,soit
has performance that is essentially better than
performanceofajettabsystem.
INTRODUCTION
Thrustvectorcontrol(TVC)isusedinrocketpropulsionto
control rockets flying path. Mathematical model,
presented in the paper, was developed as a part of the
nationalprogramfortheresearchanddevelopmentofthe
low cost cosmic transportation systems. Research in the
field was initiated in the Jet Propulsion Laboratory of
Mechanical Engineering Faculty University of Belgrade in
1983.Jettabanddomedeflectorwereselectedtobethe
objects of the research because of their simplicity,
abundance of previous tests and data, and the fact that
Fig.1 Segmented dome deflector at solid rocket motor

nozzle(R73airtoairrocket)
59
N. Davidovi, et al.
Jet Tab and Dome Deflector TVC in Solid Rocket Motor Mathematical Model and Test Comparison
Typeofobstacle(spoiler,domedeflector)
Threetypesoftestswereperformed[1]:
wind tunnel tests with measuring pressure
distributionandflowvisualization,Fig.4
laboratorytestswithflowvisualization,Fig.2
tests with air and rocket propellant gases with
measurementofforce
The main difference from flat plate tests is that Mach
number is not constant along the main oblique shock
wave causing a curved shape. Another difference, when
testing real solid rocket motor boundary layer is not
isothermal.Thisimportantfactswetookintoaccountfor
modeling.
Its application is known and widely present in many

Russian tactical and longrange missiles.Segmented
domed deflector is similar to dome deflector, but it uses
only one segment of the dome. It enables usage of two
segmented deflectors, thus giving possibility to control
missilearoundbothperpendicularaxes.
PHYSICALANDMATHEMATICALMODELOF
DISTURBEDFLOWINTHENOZZLEWITHJETTAB
Whenanobstacleispresentinthenozzlesexitarea,the
flow will turn its direction, which will cause a change in
thrust vector. Change in direction is realized through the
flowwhichcanbedescribedasfollowing[1]:indivergent
part of the nozzle, at distance Ls from the exit cross
section,anobliqueshockwaveoccurs(1).Boundarylayer
is becoming thicker with lambda shape (5) before
separation point causing compressible (4) and expansion
shock waves (3). In the disturbed zone, one recirculation
zone exists, which is forming a socalled liquid wedge (6)
[2].Infrontof(before)theobstacle,anormalshockwave
isformed(9).Atpoint(7)normalshockwaveisinteracting
with wave generated by the flow structure, after
separation point, thus allowing for the mass interchange
between zones. Flow interchange with recirculation zone
isestablishedthroughthemixturelayerwithmainstream
(2)andwithmasslossesthroughthenozzleobstaclegap.
Atthetopoftheobstacle,theflowisacceleratingthrough
theexpansionwaves(8)asinFig.3.
Fig.2 Flow visualization at Jet Propulsion Laboratory

Faculty of Mechanical Engineering University of Belgrade
[1]
Fig.4Schlierenphotofromwindtunneltestsfor=70and
90[5]
Fig.3Schemeofphysicalmodel[1]
In order to calculate forces, it is important to know the
pressuredistributionalongdisturbedzoneandobstacle.It
can, logically, be concluded that flow (and consequently
pressure distribution) depends on following parameters
(whichwerevariedintests):
RelativeblockedareaofexitnozzleAz=Ab/Ae
Relativegapbetweenanobstacleandexitnozzle
crosssection=a/De
Anglebetweenanobstacleandnozzle
Fig.5Modeldesignationsinmathematicalmodel
60
0.50
Through the analysis of the results from all performed

tests,themostsuitedengineeringmethodforcalculation
of TVC performances was recognized. Considering the
factsthatthetestswereperformedon2Dor3Dnozzles,
withjettabanddomeddeflector,withhotgasorair,with
measuring pressure distribution or measuring force, the
following method is being proposed, according to Fig.5.
The real 3D nozzle should be transformed to the
equivalent2Dnozzleby:
D 2D
D 3D
4
Ae
Ae
2D
3D
Acr
Acr
2D
3D
(1)
r 3D
r 2D
Inthecaseofjettab:
Pa/Po=f(Ls)
0.45
0.40
Relative pressure
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0.00
0
10
11
12
Coordinate along nozzle wall (cm)
0.50
Pc/Po=f(Ls)
0.45
0.40
Az 2D
Relative pressure
0.35
0.25
0.20
0.15
0.05
0.00
0
10
11
12
Coordinate along nozzle wall (cm)
0.35
Pof/Po=f(h)
0.30
0.011
0.25
0.20
0.15
0.10
1.385
0.05
Coordinate along obstacle (cm)
0.35
Az
Pob/Pe=f(h)
0.30
Relative pressure
0.25
0.20
0.15
Az
0.17
f nozzle type
1.22
(6)
adjustmentfor2Dnozzleis
0.10
f nozzle type
1 62.18 e .
cos 0.93
M1
(7)
whilefor3Df(nozzletype)=1.
Calculate the average pressures before and after the

obstacle,accordingtoFig.5
0.05
0.00
0
Coordinate along obstacle (cm)
Fig.6 Typical pressure distribution from test (area A, C,

obstaclefrontandback,respectively)[6]
61
189.17
f ,
(5)
e
CalculateaveragepressureindisturbedregionCPp:
Pp
M
p
1 0.2
f
f
.
Po
M
1
0.00
0
1.6889 Az 3D
2.853 Az 3D
2.8912 Az 3D
(2)
2D
3D
Inthecaseofdomedeflectorwehave:
Az 2D
Az 3D
2D
3D
(3)
2D
3D
Theproposedmethodologyalgorithmis:
CalculatepositionofshockwaveLs:
From the analyses, the following correlation was
established:
Ls
1.385 Az .
189.17 Az
e
Xiz
f ,
f ,
1 0.47
1.22 .
1 . (4)
o
forthenozzleanglesd20 ,otherwiseitwas:
0.30
0.10
Relative pressure
N. Davidovi, et al.
N. Davidovi, et al.
Averagepressurebeforetheobstacle,iscalculatedas:
1.15
wherefunctiondependsonMachnumberofparameter
z,whichisdefinedas:
whenz4.5functionisdefinedas:
1.66256 2.1424
0.6018
10
0.01721
1.56375 10
(9)
1.9446
(10)
Otherwiseitisdefinedas:
2.6
(11)
AdjustmentsforthegapandBetaangleare:
1
(18)
Thrustvectorangleiscalculatedas:
Calculaterelativeforces
Relativeforcesarecalculatedaccordingtothethrustina
nondisturbed nozzle. The wellknown equations for the
thrustare:
(19)
(8)
(20)
andratioofsidetothrustlossforceiscalculatedas:
(21)
(11)
MATHEMATICALMODEL,COMMENTSAND
COMPARISONOFTESTRESULTS
1.256 2.77
0.755
Averagepressureaftertheobstacleiscalculatedas
.
1
0.6 2.74
(12)
whereBetaanglecorrectionis
(13)
1 0.1844
0.151
Calculatesideandaxialforcedifference
Forces acting on divergent part of the nozzle, with an
obstacle,are:
(14)
Furtherinthepaper,graphsfromthemathematicalmodel
are being presented, Fig. 8 and 9. They contribute to the
general discussion on geometrical effect on TVC system.
Followingcanbeconcluded:
Fortheallgraphvaluesbellow5%ofblockedareaare
not confirmed because tests were not performed
withsuchavalue.Also,inthatareaboundarylayeris
of the order of the blockage which can have very
stronginfluence.
Side and thrust vector loss force are increasing
almost linearly with blockage area in engineering
usedregionfrom5to20%.
WithincreasingBetaanglefrom70o(normaltoflow)
side force and thrust vector angle is increasing (jet
tab to dome deflector). Thrust loss is also increasing
butratioofforcesisbetterwithincreasingBetaangle
after10%ofblockage.
Withincreasingthegapbetweenobstacleandnozzle
efficiencyofthesystemisgenerallydecreasing.
Smaller values of nozzle divergent angle are
increasing the system efficiency but it is usually not
designparameterfortheTVCsystem.
Forces acting on divergent part of the nozzle, with no

obstacles,are:
(15)
1
Forcesactingonthefrontsideoftheobstacleare:
(16)
Forcesactingonthebacksideoftheobstacle:
(17)
Fig.7MotoratteststandatEDeProcompanysite
Resultantforcesare:
62
Comparison with test data (Fig.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. It is very difficult to predict
pressureaftertheobstacleforgreatervaluesofblockage
which is causing differences between model and test.
Tests were performed with real rocket motor and six
components test stand at EDePro company site
(www.edepro.com),Fig.6.
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. Its
accuracy, when compared against the experimental
results,isexcellentintheareabetween5and20%ofthe
blockage. Side force shows complete linear behavior,
which is preferable for control. The model uses
engineeringdesignparameterssuchasdand,andalso
control parameter Az which gives this method an
engineeringcharacterandpracticalusage.
0.30
0
=1%,d=20
0.28
0.26
=110
Relative side force
0.24
0.22
=90
0.20
Acknowledgement
Research of this paper is result of the national project

financedbySerbianMinistryofEducationandScience(TR
35044).
0.18
0.16
=70
0.14
0.12
REFERENCES
0.10
[1] B.Joji. .Blagojevi,V.Fotev,M.Marko and others:

Rocket propulsion researchthrust vector control, Jet
Propulsion Laboratory Faculty of Mechanical
EngineeringUniversityofBelgrade,19841986.
[2] G.N.Abramovi: ,
,Moscow,1976.
[3] R.G.Eatough: Improved jet tab thrust vector control
fortheBGM34Cbooster,AFRPLTR7749,1977.
[4] B.Joji,
M.Milinovi,
Z.Stefanovi,.Blagojevi:
Pressuredistributioninrocketnozzlewithmechanical
system for TVC, AIAA Propulsion Conference, San
Diego,1987.
[5] Z.Stefanovi: Research of fluid flow and pressure
distribution in supersonic nozzle in connection with
vector thrust control, PhD thesis, Faculty of
MechanicalEngineeringUniversityofBelgrade,1986.
[6] B.Joji and others: Research from modern rocket
propulsionTVCphysical model, Jet Propulsion
Laboratory Faculty of Mechanical Engineering
UniversityofBelgrade,1986.
0.08
0.06
0.04
0.02
0.00
0.00
0.05
0.10
0.15
0.20
0.25
0.30
Blocked area
Fig.8Relativesideforcevs.blockedareafordifferentbeta
angle
0.30
=1%,d=20
0.28
0.26
Relative thrust loss
0.24
=110
0.22
=90
0.20
0.18
=70
0.16
0.14
0.12
0.10
0.08
0.06
0.04
0.02
0.00
0.00
0.05
0.10
0.15
0.20
0.25
Fig.9Relativethrustlossvs.blockedareafordifferentbeta
angle
Relative force
0.25
0.20
Model
Az=5%, Fyr=4.9%, Fxr=0.4%
Az=10%, Fyr=10.4%, Fxr=1.9%
Az=15%, Fyr=15.6%, Fxr=4.1%
Az=20%, Fyr=20.7%, Fxr=7.5%
0.30
Blocked area
0.30
Fyr
Test
Az=5%, Fyr=5.6%, Fxr=0.3%
Az=10%, Fyr=9.9%, Fxr=1.6%
Az=20%, Fyr=19.9%, Fxr=6.0%
Model
0.15
Fxr
Test
0.10
Ref. 3
0.05
0.00
0.00
0.05
0.10
0.15
0.20
0.25
Relative blocked area
Fig.10Mathematicalmodelandtestcomparison
0.30
63
N. Davidovi, et al.

TheProceedings
The Comprehensive Comparison of the Selected Cutting Materials

with Standard ISO 3685 in Machining Process of Steel C60
JanDuplak1ImrichOrlovsky2
1
PhDStudentofManufacturingEngineering,UniversityofKosice,FacultyofManufacturingTechnologies,Slovakia,Email:jan.duplak@tuke.sk
PhDManufacturingEngineering,ResearchEngineer,UniversityofKosice, FacultyofManufacturingTechnologies,Slovakia,Email:imrich.orlovsky@tuke.sk
ARTICLEINFO:
Abstract:
Durability
Cuttingspeed
StandardISO
F.W.Taylor
Turning
The main part of Standard ISO 3685 is T-vc dependence for various cutting materials. The Standard ISO 3685
contains main properties and characteristics for three most important cutting materials those are used in
engineering practice. These cutting materials are used for cutting tools made of high speed steel, cutting ceramic
and sintered carbide. Some types of cutting materials are defined by means of descriptions in standards ISO, some
types by means of catalogues from the manufacturer. 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. There is a
presumption that descriptions in standards ISO are not correct and these standards have to be examined and
verified, because that this fact have to be confirmed or disproved. 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, cutting ceramic and sintered carbide, because were found deficiencies in
valid standard ISO 3685.
Citation:DuplakJ,OrlovskI.hecomprehensivecomparisonoftheselectedcuttingmaterialswithstandardISO3685inmachiningprocessofsteelC60,2ndInternationalConference
NOMENCLATURE
ap
f
vc
T
VB
is based primarily on favorable material properties.

As a class of materials, ceramics possess high melting
points, excellent hardness and good wear resistance.
Ceramics are also chemically inert against most work
metals.[3,7]
Cuttingdepth
Feed
Cuttingspeed
Durability
Criterionofdepreciation
GRAPHICSDEPENDENCEVB=f(s)
GraphicsdependenceVB=f(s)fordifferentcuttingspeeds
was
described with Frederick Winslow Taylor in 1906.
Verification of standards is very difficult process. 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. Dependences that are
experiment.Afteranalyzingofoutputsfinaldependencies
describedbyTaylorarerelevantonlyforhighspeedsteel,
canbedescribed.Intechnicalsciencesaredescriptionsfor
because in that time high speed steel was only available
each experiment, realization of process or adequate
forTaylorexperiments.[10]KnowledgedefinedbyTaylor
choiceofcuttingtools,materials,technologicalconditions,
is used in standard ISO 3685. Standard ISO 3685 obtains
cutting parameters and theirs application. [16]
testsofdurabilityofcuttingtoolsforworkpiecesmadeof
In engineering can be used for experiments a lot of
steel and cast iron. This standard includes only cutting
different technological operations. One of these
tools made of high cutting steel, sintered carbide and
operationsisturning.Turningisthemostbasicprocessin
cutting ceramic. Standard is valid only for conditions,
machining,becauseitforms30%fromalltechnologiesof
when the criterion of durability is defined as tool wear.
machining. [15] In the turning there are many types of
[14]
cutting tools used made of different materials. Some of
these materials are high speed steel, cutting ceramic,
STANDARDISO3685ANALYSIS
sinteredcarbide.Highspeedsteel(HSS)isasubsetoftool
steels, usually used in tool bits and cutting tools. It is
The standard ISO 3685 describes for all cutting materials
superior to the older high carbon steel tools used
common Tvc dependence. Current valid relation
extensively through the 1940s in that it can withstand
of Tvc dependence is described by Taylor formed basics
higher temperatures without losing its hardness. This
of standard ISO 3685. Tvc dependence was designed
property allows HSS to cut faster than high carbon steel,
according to Taylor in logarithmic scale. [12] Very
hencethenamehighspeedsteel.[1,8]Sinteredcarbideis
significant problem in standard ISO 3685 is evaluation of
unique combination of strength, hardness and toughness
results. Characteristics and dependences for all cutting
satisfies the most demanding applications. [2,6] A key
materialsaresame.[6]
featureofthesinteredcarbideisthepotentialtovaryits
composition so that the resulting physical and chemical
THE WAYS OF RESULTS EVALUATION ACCORDING
properties ensure maximum resistance to wear,
TOSTANDARDISO3685
deformation, fracture, corrosion, and oxidation. [4,9]
Ceramiccuttingtoolshavebeeninuseforapproximately
StandardISO3685describesmoremethodsforsolutionof
90years.However,asnewcuttingtoolsweredeveloped,
Tvc dependence. 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. [5,11,13]
forobtainingoftesteddependences.[12]
Interest in ceramics as a high speed cutting tool material
INTRODUCTION
64
The Comprehensive Comparison of the Selected Cutting Materials with Standard ISO 3685 in Machining Process of Steel C60
J.Duplak, I. Orlovsky
StandardISO3685indicatesthesemethodstoobtainthe
3) Construction Tn=f(vc) dependence in logarithmic scale
results:
and determination index of machinability for selected
To toggle the line through measured points durabilityundercomparisoncuttingspeedtestedmaterial

(approximation)
andetalonmaterial.[12]
Methodofleastsquares
Interpolation of dependence into unmeasured

fieldofcuttingspeeds
Guessevaluation
THE DURABILITY ON THE BASED OF

TVCDEPENDENCEACCORDINGTOSTANDARDISO
TaylordefinedTvcdependenceaccordingtoexperiments
made with high speed steel. These tests according to
standard ISO 3685 are valid for all cutting materials. The
standard ISO 3685 contains information about Tvc
dependences for high speed steel, sintered carbide and
cuttingceramic.[10]
MACHININGLONGTERMTESTMETHOD
Essentially there is only one machining longterm test
method.Criterionisvalueofcuttingspeedanditisdone
by turning or milling with described constant cutting
parameters, type of cutting tool with defined geometry

Fig.3Tvcdependenceinlogarithmicscale[12]
andgraduatedcuttingspeedstotheoptimaltipblunting.
Thistestisconsideredasbasicandthistestsetmeasuring
objectivityofmachinabilityfor otherstests.Disadvantage
EXPERIMENTSWITHCUTTINGTOOLS
of this test is consumption of workpieces and time
Firstveryimportantstep,beforetheactualexperimentsis
consumption.[10]
specification of technological system. In technological
system for these experiments were contained machine
toolworkpiece.
Descriptionofmachininglongtermtestmethod:
1)Timemeasurementprocessofdepreciationonbackof
tool VBB, for few value of cutting speeds at constant
cuttingparametersandconstructioncurveofblunting.
Fig.1Curveofbluntingforvariablecuttingspeeds[12]
Fig.4Technologicalsystemforexperiments
Workpieces for experiments are made of steel C60.
Material for workpieces is from specific material list with
guaranteedchemicalstructureandmechanicalproperties.
Tab.1ChemicalstructureofC60
2) Specification criterion of depreciation VBopt and

determinationtipdurabilityforeachcuttingspeed.
ChemicalstructureofC60[%]
C
Mn
Si
Cr
Ni
Cu
0,57
0,65
0,60
0,90
max.
0,40
max.
0,40
max.
0,40
max.
0,19
max.
0,030
max.
0,020
Tab.2MechanicalpropertiesofC60
Rm[MPa]
900
13
255
Rp0,2[Mpa]
580
These experiments were made under defined

technological conditions. Tool durability was proven with
kinetic machining longterm test method. Experiment
inputswereworkpieceswithequaldiameters;thosewere
used at turning process. For each cutting speed the
Fig.2 Determination of particular durability by the

criterionofdepreciation[12]
65
MechanicalpropertiesofC60
A5[%]
HB
diametershouldhavethesamevalue,becauseexamined
material has different consistency in different depth.
Experimentwasfinishedoncewearcriterionwasreached.
TECHNOLOGICAL CONDITIONS USED FOR HIGH

SPEEDSTEEL
vc = 2 100 m.min1; ap = 0,5 mm; f = 0,3 mm ;
r=0,5mm;r=75;r=15;VB=0,3mm;o=6
Tab.3ResultsofTvcdependenceforHSS
vc,m.min1
T,min
vc,m.min1
2
105
35
2,5
97
41
3,3
88
52
11
33
58
13
22
87
22
21
100
28
14
T,min
8
6
3,3
2,8
1,5
1,2
Fig.6TvcdependenceforAl2O3inlogarithmicscale
TECHNOLOGICALCONDITIONSUSEDFORSINTERED
CARBIDE(P20+TIN)
vc = 5 350 m.min1; ap = 0,2 mm; f = 0,3 mm;
r=0,8mm;r=80;r=10;VB=0,3mm;
Tab.5ResultsofTvcdependenceforP20+TiN
vc,m.min1
T,min
vc,m.min1
T,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.5TvcdependenceforHSSinlogarithmicscale
TECHNOLOGICAL CONDITIONS USED FOR CUTTING

CERAMIC(AL2O3)
vc = 2 550 m.min1; ap = 0,2 mm; f = 0,3 mm ;
r=0,8mm;r=80;r=10;VB=0,3mm;
Tab.4ResultsofTvcdependenceforAl2O3
vc,m.min1
T,min
vc,m.min1
T,min
2
55
139
25,5
8
35
147
25
Fig.7TvcdependenceforP20+TiNinlogarithmicscale
12
22
153
21
16
19
158
20,7
CONCLUSIONS
17,5
18
188
14
Every one process in engineering industry is defined by
22
16,8
225
10
some standard ISO. Procedures for technical sciences are
35
15
235
9,5
defined in standards these standards described
49
26,5
253
9
technological conditions, dependencies, settings, diverse
51
27
268
8,9
cutting parameters etc. Precision and completeness of
55
27,5
380
7,2
standard ISO represents primary factor in technical
85
28,3
440
6,3
sciences. Defects and imprecision described in standard
100
29,5
510
6
ISO need to be fixed. Experiments are necessary to
130
27
530
5,8
prevent false information. This paper was oriented on
136
26
550
5
durability selected ceramic cutting plates in machining
processofsteelC60.Thedurabilityissueofcuttingtoolsis
defined in standard ISO 3685. This standard defines all
process how to create and to define cutting tools
durability by means of Tvc dependence according to
Taylor. Executed experiments showed, that between the
standard ISO 3685 and experiment results are expressive
differences. The following figure (8) shows differences
66
REFERENCES
between standard ISO 3685 and selected ceramic plates.

Experiment was executed for selected types of cutting
plates and for all three types are in graph visible
differences. Following figure shows differences between
Tvc dependence from standard ISO 3685 and Tvc
dependenciesfromexperimentsresults.
[1] A.Helmi,Y. and H. ElHofy, Machining Technology

Machine Tools and Operations, CRCPress, pp.398,
2008,ISBN9781420043396
[2] A.Panda.et.all., Accompanying phenomena in the
cuttingzonemachinabilityduringturningofstainless
steels., International Journal Machining and
Machinability of Materials, INDERSCENCE Publisher,
Switzerland. ISSN 17485711(print), ISSN 1748572X
(online).Vol.5,No.4,2009,383400p.
[3] B.S. P. Nagendra, R.K.Mittal, Elements of
ManufacturingProces,PrenticeHallofIndiaPrivate
Limited,pp.496,2006,ISBN9788120319585
[4] E.Isakov,CuttingDataforturningofsteel,Industrial
Press,Inc.989AvenueoftheAmericasNewYork,NY
10018,pp.316,2009,ISBN9780831133146
[5] E.D.Whitney, Ceramic Cutting Tools, William
Andrew
Publishing/Noyes,
pp.353,
1994,
ISBN9780815513550
[6] J. T. Black,R.A.Kohser,Degarmo's Materials &
Processes In Manufacturing, Wiley India Private
Limited,pp.1032,2007,ISBN9780470055120
[7] J. NovakMarcincin.et.al. Applications of computers
in manufacturing engineering, AEI 2011:
international conference on applied electrical
engineering and informatics 2011 : September 310,
2011, s.l., Italy. Koice: TU, 2011 P. 1014. ISBN
9788055307404
[8] J.Zajac. et.al., Cutting facilities of new type ofcame
cutting material, Proceedings of the conference
PPTO,Koice,1995,pp.138139
[9] K.Vasilko, Theory and practise of splinter
machining,
Preov
FVT,
pp.
546,2009,
ISBN9788055301525
[10] M. Cuma, M. Janak, The impact of cutting fluids on
machining, 2009. In: ICPM 2009. Preov FVT TU,
2009p.2530.ISBN9788055302430
[11] M.Hatala. et.al.,Production technology of spindle
part,In:ManufacturingEngineering,2009p.1922.
ISSN13365967
[12] M.Nesluan.et.al., Experimental methods in splinter
machining, EDIS U ilina, pp.343,2007, ISBN 978
8080707118
[13] P.Michalik, J.Zajac," Intelligently programming of
holes machining", In: Manufacturing Technologies .
Vol.9,N.4(2010),s.6365.ISSN13357972
[14] R.ep, M.Nesluan, B.Barii, Chip Formation
AnalysisDuringHardTurning,Engineering,2008,vol
50,No.6,p.337345.ISSN05621887
[15] S.Hloch, J.Valek, Prediction of distribution
relationship of titanium surface topography created
byabrasivewaterjet,2011.In:InternationalJournal
of Surface Science and Engineering. Vol. 5, no. 2/3
(2011),p.152168.ISSN1749785X
[16] .Gapar, J.Maenik, J.Pako, The effect of
degassing pressure casting molds on the quality of
pressure casting, 2012. In: Advanced Materials
Research.Vol.428(2012),p.4346.ISSN10226680
Fig.8 Standard ISO 3685 Tvc dependence and Tvc

dependenciesfromexperimentscomparison
Deeperexplorationofdurabilitycuttingmaterialsdefined
instandardISO3685isveryimportant,becauseonlyvalid
informationandcorrectdependenciesmaybeincludedin
technicalstandards.
Fig.9Examplesofusedcuttingplates
67
68
DearDelegates,dearAuthors,
our work, our imagination, our knowledge, our attitudes determine our
being...butsometimeswedontunderstand...
Thispageisdedicatedtomemoryofprof.Ing.PeterFeko,PhD.,memberof
ICMEM Scientific Committee (VBTU Ostrava), who left us forever on
10.03.2012ontheageof51years.
Yougaveusalot.Peter,thankYou,thatwemayknowanoutstandingscholar,
teacher,andgreatfriendwithbighearthwhoreallylovedthisworldwithsmile
onyourface.Youaregreatlymissedforyourenormousintellect,yourendless
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69

TheProceedings
Influence of Factors of Plasma Cutting on Surface Roughness and

Heat Affected Zone
MichalHatala1NicolaeUngureanu2PeterMichalik3JnDuplk4ubomrOlexa5MiroslavKormo6
1
FacultyofManufacturingTechnologiesofTechnicalUniversityinKoicewithaseatinPreov,email:michal.hatala@tuke.sk
PhDMechanicalEngineering,FullProfessor,Facultyofengineering,NorthUniversityofBaiaMare,Romania
PhDMechanicalEngineering,Lecturer,FacultyofManufacturingTechnologiesofTechnicalUniversityinKoicewithaseatinPreov
4
PhDstudent,FacultyofManufacturingTechnologiesofTechnicalUniversityinKoicewithaseatinPreov
5
6
2
3
ARTICLEINFO:
Category:Preliminarycommunication
Abstract:
Plasmaarc
Factoranalysis
Quality
Almost every technological process can we currently predict somewhat. The article presents the design and
evaluation of plasma arc cutting technological process. Influence of technological factors on roughness parameters
Ra of the steel surface EN ISO S355 have been evaluated using planned experiments. Using factor experiment 24,
the significance of the four process factors: plasma burner feed speed, plasma gas pressure, nozzle diameter,
distance between nozzle mouth and material have been observed. Regression models obtained by multiple linear
regression indicates the quality level as observed factors function. The heat from plasma arc is affected the
microstructure of the material too. The heat used for cutting of material affects its microstructure changes.
Citation:HatalaM.,etal.: InfluenceofFactorsofPlasmaCuttingonSurfaceRoughnessandHeatAffectedZone,2ndInternationalConferenceManufacturingEngineering&Management
2012,(2012),p.7073,ISBN9788055312163
INTRODUCTION
Modern industry depends on the manipulation of heavy
metal and alloys. We need metals to build the tools and
transportation necessary for daytoday business. For
example, we build cranes, cars, skyscrapers, robots, and
suspension bridges out of precisely formed metal
components. The reason is simple. Metals are extremely
strong and durable, so they're the logical choice for most
things that need to be especially big, especially sturdy, or
both. The funny thing is that metal's strength is also a
weakness.
Because metal is so good at resisting damage, it's very
difficulttomanipulateandformintospecializedpieces.So
how do people precisely cut and manipulate the metals
needed to build something as large and as strong as an
airplane wing? In most cases, the answer is the plasma
cutter.Itmaysoundlikesomethingoutofascifinovel,but
theplasmacutterisactuallyacommontoolthathasbeen
aroundsinceWorldWarII.
Fig.1Thegeneralprincipleofplasmacutting
Conceptually, a plasma cutter is extremely simple. It gets

the job done by harnessing one of the most prevalent
statesofmatterinthevisibleuniverse.Inthisarticle,we'll
cutthroughthemysterysurroundingtheplasmacutterand
see how one of the most fascinating tools has shaped the
world around us. Plasma is the fourth and most highly
energized state of matter: solid, liquid, gas and then
plasma. In fact, plasma looks and behaves like a high
temperature gas, but with an important difference it
conductselectricity.Theplasmaarcresultsfromelectrically
heating a gas (typically air) to a high temperature. This
ionizesgasatomsandenablesthemtoconductelectricity.
A fluorescent light is an example of plasma in action. A
plasmaarctorchspinsagasaroundanelectrode.Thegasis
heated in the chamber between the electrode and torch
tip,ionizingthegasandcreatingplasma.
ADVANTAGES AND DISADVANTAGES OF PLASMA

CUTTING
Advantages:
better cut quality when cutting thick materials
(comparetoflamecutting)
cheaperthanlaserforcuttingofthinsheets
lowimpactofworkingenvironment
suitable for thicker sheets with medium demand
oncutedgequalityandcorrectness
high cutting speed (depends on material
thickness)
possibilityofreachinggoodsurfaceroughnessfor
steelsandanticorrosionsteels
simplereplacementofthroat,electrode,torch
relativelywidethicknessextentofcutmaterials
Disadvantages:
noiselevelraiseswithraisingofcurrent
cannotcreateneitherlittleroundsofcutedgenor
straitgroove
seriouscutwidth
differentcutquality/badsidegetstowaste)
harmfulsteamsensuing(exhaustingneeded)
70
Influence of Factors of Plasma Cutting on Surface Roughness and Heat Affected Zone
M. Hatala, et al.
CONDITIONSOFEXPERIMENTPLANNING
Theprocessparametersarecausedincommoninteractivity
in praxis with plasma cutting. For the analyzing of this
model is used factors experiment. This experiment
evaluates combinations of all planning factors. As
experimental material was constructional steel ISO Fe510
with6mmthicknessandtheplasmagaswasair.Wemade
fortheexperiment16piecesofsamples.
Factors:
nozzlediameter,
plasmaburnerfeedspeed,
plasmagaspressure,
distancebetweennozzlemouthandmaterial.
Tab.1Tableofreallevelvaluesoffactorsofexperiment
Factors
N
Marking
Intervalof
factors
1
+1
Description
value
nozzle
mm
1
1,2
diameter (d)
plasma
2
2
burnerfeed m/min1
0,6
0,9
speed(v)
plasmagas
MPa
0,55 0,68
3
3
pressure(p)
distance
between
nozzle
mm
4
4
6,6
7,8
mouthand
material(z)
In this example we have four factors, it is thus
tetradimensionalmodel.Bytwolevelsofdifferentfactors,
where particular levels are coded as 1 and +1 it presents
full factor of 2k type. Than for four factors particular
attemptswillberealizedin24=16differentrelations.Such
twoleveled factor experiment will be used for simple
specification of factors, that statistically significantly im
pactthevariabilityofvaluesofvariablesyRa,yRz,y.
By the exact test that besides main factors includes also
interactionsoffallcombinationsoffactorsandlevels,there
can be investigated the impact of all potentially possible
combinationsoffactorsandaftereliminationofstatistically
notsignifiedfactorsitcanbemovedtomoredetailedand
accurateexperimentalschemes.Tothecodedvaluesof1
and +1 levels, that presents the level of observed area of
particular factors, there have been assigned real level
valuesofthesefactors.(Tab.1).
1
Fig.2aTheprocessparametersandfactoranalysis
Fig.2bTheprocessparametersandfactoranalysis
The roughness was measured in two lines, one and five

millimetersfromupperedge.Measurementwasrealizedby
apparatus Mitutoyo . Roughness of surface is create by
anomalies of surface with small separation, which are
including anomalies from the different technology of
manufacturing or another effects. We suppose that these
anomalies are within defined borders, for example in
borderofprimarylength.
Measurementinfirstline
Significationofbearingformonitoredfactorstoparameter
ofroughnessRaindistanceonemillimeterfromupperedge
isshovedinParetsgraph(Fig.3.).
Fig.3Paretsgraphfordistanceonemillimeterfromupper
edge
Fig.4Graphofmarginaleffects
71
M. Hatala, et al.
TheresultfromParetsgraphisthemostinfluenceforthe
roughness Ra factor of the plasma burner feed speed.
From Parets graph it is obvious, that highest impact to
middlearithmeticaldeviationofsurfaceroughnesshasthe
feed factor of plasma torch. Significant impact to the
qualityofmachinedsurfacehasalsothepressureofplasma
gas. Lower impact to the quality presents the nozzle
diameter.Lowestimpactispresentedbydistanceofnozzle
mouthfrommaterial.Afterrealizationofhypothesisabout
importance of particular equations coefficients and
eliminationofnotsignifiedfactorsoutoflinearregression,
final equation was acquired, that express the middle
arithmetical deviation of Ra profile in relevant measured
depthh=1mm.
Measurementinsecondline
Significationofbearingformonitoredfactorstoparameter
of roughness Ra in distance five millimeters from upper
edgeisshovedinParetsgraph(Fig.4.).
Fig. 7 Relief surfaces after cutting of plasma arc, thickness

10mm
HEATAFFECTEDZONEAFTERCUTTING
Fig.5 Paretsgraphfordistancefivemillimeterfromupper
edge
Fig.6Graphofmarginaleffects
FromParentsgraphitisobvious,thathighestimpacttothe
middlearithmeticaldeviationofsurfaceroughnesshasfeed
factor of plasma torch. Significant impact has also the
pressure of plasma gas. Minimal impact level is presented
bynozzlediameteranddistancebetweennozzlemouthand
material.
Investigationsofmicrohardnessshowedthat,themaximum
valueimmediatelyatthecutsurfaceincreasesappreciably
about255HV1inthedepositacrossadistanceof0,7mm
(thickness 20 mm), about 240 HV1 in the deposit across a
distanceof0,5mm(thickness15mm)andabout110HV1
in the deposit across a distance of 0,4 mm (thickness 10
mm).Themicrohardnessisconnectedbasicallytothelocal
changesinmechanicalpropertiesofthematerial.Itcanbe
seen little difference in microhardness that results in
narrow HAZ. The microstructural damage zone (heat
affectedzone)isapproximately0,7deep.Theheataffected
zonefromaplasmacutisnarrowerandpeakharnessesare
higher than that produced for example by flame cutting.
Austeniteformationisfoundtobecomplexwhileheatedto
a temperature 741 C (in between Ac1 and Ac3
temperatures).Theresultofthisshowcontinuedgrowthof
austenite. Passing the eutectoid temperature during
cooling requires a radical change. Practically all the
homogeneously dissolved carbon now has to go to the in
homogeneously distributed cementite by diffusion. The
austeniteisquenched,i.e.rapidlycooled.Thecarbonstays
in place more or less and this necessarily prevents
pearliteandferriteformation.Instead,anewlatticetypeis
found, called "martensite". Its volume is getting down to
the core of base material. HAZ goes through the narrow
zone of normalization with fine grained structure and
considerably wider zone of partial pre crystallization.
Damaged created by a plasma torch cut microstructure
was originally a bandedpearlite and ferite, 3% picral etch.
Originalmagnification63xa600x.
72
M. Hatala, et al.
Fig.9 The resulting cracks in steel S355J0 after plasma

cutting500x
HAZFindings
AllofthisHAZmeasurementswerebetween0,4
0,7mm.
HAZ varies with speed and power. The extent of
the HAZ in low steel is related to process
variables,suchascutspeedandpower,aswellas
materialthickness.
REFERENCES
[1]
Fig.8Heataffectedzonezoom63xa600x
[2]
CONCLUSIONS
Paper deals with definition and evaluation of process
factors and parameters of cut surface while cutting the
material EN S355J0. Methods of planned experiments are
used for these evaluations. Using factor experiment,
importance of four factors was observed (feed rate of
plasma torch, plasma gas pressure, nozzle diameter and
distance between nozzle mouth and material), that
influencetheparameterofroughnessprofileRaandRz.On
the base of results that were analytically processed by
factor analysis it can be said, that impact of process
parameters during the material cutting was different in
particular depths. It was found out, that most significant
impact to the machined surface roughness has factors of
feedrateofplasmatorchandplasmagaspressure.Among
other factors that are less important belongs diameter of
nozzle and distance between nozzle mouth and material.
From the experimental results it can be said, that for
achievinghigherqualityofcutsurfaceitisrecommendedto
use higher pressures of plasma gas and appropriate feed
rateofplasmatorch.
[3]
[4]
[5]
[6]
[7]
73
Buschow, J.: (2001). Encyklopedia of materials:

Science and technology, volume 7. Elsevier, London,
2001,ISBN0080431526
Kubica, P.: (2009). Factor Analysis of Plasma Arc
Cutting Technological, Diploma Thesis, Faculty of
Manufacturing Technologies, Technical University of
KoicewithaseatinPreov,Preov.
Mayers, A. Ramtech: (2002). Encyklopedia of
physical science and technology, volume 12.
AcademicPress,California,USA,ISBN0122274229.
uma, M. Zajac, J.: The impact analysis of
cutting fluids aerosols on working environment and
contaminationofreservoirs,In:Tehnikivjesnik.Vol.
19,no.2(2012),p.443446.ISSN13303651.
Orlovsk,I.Zajac,J.:Mathematicalmodelofthe
spraydry,In:ICMaS:proceedingsoftheInternational
Conference of Manufacturing Systems: 5 6
November, 2009, Bucharest, Romania: Vol. 4.
Bucharest: University Politehnica, 2009 P. 275 278.
ISBN18423183.
omkov, Z. Tarasoviov, A. Kasina, M.: Study
of materials with natural reinforcement and
thermo plastic matrix (Wood Plastic Composite), In:
InternetJournalofEngineeringandTechnologyfor
YoungScientists.Ro.1,.1(2010),s.16.ISSN1338
2365.
Monkov,M.Monka,PVegnerov,P.ep,R.
Mllerov,J.Braina,D.Duspara,M..:Factor
analysisoftheabrasivewaterjetfactorsaffectingthe
surface roughness of titanium , In: Technical
Gazette.Vol. 18, no. 1 (2011), p. 73 77. ISSN 1330
3651.

TheProceedings
Using LCR Ultrasonic Method To Measure Residual Stresses

Through Thickness of Dissimilar Welded Pipes
YasharJavadi1
1
DepartmentofMechanicalEngineering,IslamicAzadUniversitySemnanBranch,Semnan,Iran,Email:yasharejavadi@yahoo.com
FacultyofManufacturingTechnologiesTUKEwithaseatinPreov,SlovakRepublic,Email:hloch.sergej@gmail.com
ARTICLEINFO:
Category:OriginalResearchPaper
Abstract:
UltrasonicStressMeasurement
AcoustoelasticEffect
WeldingResidualStress
LCR
DissimilarWeldedJoint.
Ultrasonic stress measurement is based on acoustoelasticity, i. e. the relationship of stress and wave velocity in
engineering materials. This technique uses critically refracted longitudinal waves that travel parallel to the surface, i.
e. LCR waves. The longitudinal critically refracted (LCR) wave is a bulk longitudinal mode that travels within an
effective depth underneath the surface. This paper evaluates welding residual stresses in plate-plate joint of AISI
stainless steel 304L. Because of the residual stress changing through the thickness, the accurate depth underneath
the surface in LCR waves is measured for 1Mhz, 2Mhz, 4Mhz and 5Mhz transducers. After the accurate
measurement of depth, residual stresses through the thickness of plates are evaluated by four different series of
transducers. It has been shown that the residual stresses through the thickness of stainless steel plates can be
inspected by LCR waves.
Citation: Javadi,Y.,Hloch,S.: UsingLCRUltrasonicMethodToMeasureResidualStressesThroughThicknessofDissimilarWeldedPipes,2ndInternationalConferenceManufacturing

INTRODUCTION
Residual stresses are present in materials without any
external pressure, and normally result from deformation
heterogeneitiesappearinginthematerial.Theyhavevery
important role in the strength and service life of
structures. Welding is an assembly process often used in
different industries, especially in the pressure vessel
industry. According to the process and temperatures
reached during this operation, dangerous thermo
mechanical stresses may appear in the welded joint. To
achieve a proper design of structure and control their
mechanical strength in service, it is very important to
determinetheresidualstresslevelswithanondestructive
method. The high industry request for the stress
measurement techniques encouraged development of
several methods like Xray diffraction, incremental hole
drilling, and the ultrasonic waves methods. Many studies
showedthatthereisnouniversalorabsolutemethodthat
gives complete satisfaction in the nondestructive stress
monitoring of the mechanical components. Many
parameters such as material, geometry, surface quality,
cost, and accuracy of the measurement, etc., must be
taken into account in choosing an adequate technique.
The ultrasonic technique was selected for stress
measurement because it is nondestructive, easy to use,
andrelativelyinexpensive.However,itisslightlysensitive
to the microstructure effects(grains size [1, 2, 3], carbon
rate[4,5],texture[6,7,8,9],andstructure[10,11,12])
and to the operating conditions (temperature [13, 14],
coupling [15, 16], etc.). The ultrasonic estimation of the
residual stresses requires separation between the
microstructureandtheacoustoelasticeffects.
some of the authors. Brekhovskii [19], Basatskaya and

Ermolov [20], Junghans and Bray [21], Langenberg et al.
[22] had some detailed discussions on the characteristics
oftheLCR.
Fig.1LCRprobeforPMMA(Plexiglas)wedgeonsteel
Ultrasonic stress measurement techniques are based on

therelationshipofwavespeedindifferentdirectionswith
stress.Fig.2showselementsofabarundertensionwhere
the ultrasonic wave propagates in three perpendicular
directions. 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. In Fig. 2a the wave propagates parallel to the
loadandV11representsthevelocityoftheparticlesinthe
same direction (longitudinal wave), meanwhile V12 and
V13 represents the velocity in a perpendicular plane
(shearwaves).
In Fig. 2b and Fig. 2c the waves propagating in the other
directionsandthevelocitiesareshown.TheV22velocityis
for longitudinal waves propagating perpendicular to the
stress direction. The sensitivity of these waves to the
strainhasbeenestablishedbyEgleandBray[17]intensile
THEORETICALBACKGROUND
Within the elastic limit, the ultrasonic stress evaluating
technique relies on a linear relationship between the
stress and the travel time change, i.e. the acoustoelastic
effect [17, 18]. The LCR technique uses a special
longitudinal bulk wave mode, as shown in Fig.1 , which
travels parallel to the surface, particularly propagating
beneaththesurfaceatacertaindepth.TheLCRwavesare
alsocalledsurfaceskimminglongitudinalwaves(SSLW)by
74
Using LCR Ultrasonic Method To Measure Residual Stresses Through Thickness of Dissimilar Welded Pipes
Y. Javadi
termstimeofflight(dt/to),asshownintheEq.(4),where
toisthetimeforthewavetogothroughastressfreepath
inthematerialbeinginvestigated.
and compressive load tests for a bar of rail steel. The

waves with particle motion in the direction of the stress
fieldsshowedthegreatestsensitivitytostress,andthose
with particle motions perpendicular to the stress field
showed the least. The most considerable variation in
travel time with the strain was found for longitudinal
waves, followed by the shear waves when the particles
vibrate in the direction of the load. The other waves do
notshowsignificantsensitivitytothestrain.
E ( dV 11 / V11 )
E
dt
L11
L11 t 0
(4)
where d is the stress variation (MPa) and E is the

elasticitymodulus(MPa).Thesameequationcanbeused
for the other directions of the waves, provided the value
of the acoustoelastic coefficient L is changed. For a fixed
probe distance, the travel time of the longitudinal wave
decreasesinacompressivestressfieldandincreasesina
tensile field. The acoustoelastic constant (L) functionally
linksthestressandthevelocityortraveltimechange.
EXPERIMENTALPROCEDURES
Thematerialstested(stainlesssteel304andcarbonsteel
A106B) are commonly used for pressure vessel
applications.Two8inchpipeswiththicknessof8mmwere
weldedinVgroove(60includedangle)andthreepasses
buttweld joint. 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. The measurement device, shown in Figure 3,
includes an Ultrasonic box with integrated pulser and
receiver, computer and three normal transducers
assembledonaunitedwedge.Athreeprobearrangement
was used, with one sender and two receivers in order to
eliminate environment temperature effect to the travel
time. Twelve transducers in four different frequencies
were used which their nominal frequencies were 1Mhz,
2Mhz, 4Mhz and 5Mhz. Using different frequencies helps
toevaluateresidualstressesthroughthethicknessofthe
pipes.Thediameterofallthepiezoelectricelementswere
6 mm. Transducers was assembled on a united PMMA
wedge. The ultrasonic box is a 100Mhz ultrasonic testing
device which has a synchronization between the pulser
signal and the internal clock, that controls the A/D
converter. This allows very precise measurements of the
timeofflightbetterthan1ns.
Fig.2Velocityofplanewaveandstressfieldinorthogonal
directions[23]
The velocities of the longitudinal plane waves traveling
parallel to load can be related to the strain () by the
followingexpressions:
0V112 2 (2l ) (4m 4 10)1 (1)
whereoistheinitialdensity;V11isthevelocityofwaves
in the direction 1 with particle displacement in the
direction1;,thesecondorderelasticconstants(Lames
constants); l, m, n are the third order elastic constants;
1 2 3 which1,2and3arecomponentsofthe
homogeneous triaxial principal strains. For a state of
uniaxialstress,1=,2=3=,whereisthestrain
inthedirection1andisthePoissonsratio.Usingthese
values,Eq.(1)becomes:
0V112 2 [4( 2 ) 2( 2m) (1
)]. (2)
Therelativesensitivityisthevariationofthevelocitywith
the strain and can be calculated by Eq. (3). In this
equation,L11isthedimensionlessacoustoelasticconstant
forLCRwaves.
dV11 / V11
( 2m) v (1 2l / )
2
L11 (3)
d
2
The values of acoustoelastic constants for the other

directionscanbeobtainedinthesameway.Thevariation
inthev11velocity,controlledbythecoefficientL11,ismuch
greater than the other ones, indicating that these waves
arethebestcandidatestobeusedinthestressevaluation.
Stress can be calculated by the onedimensional
application of the stressstrain relations in elastic solids.
Eq. (3) can be rearranged to give the stress variation in
Fig.3Measurementdevices
75
Y. Javadi
DETERMINATIONOFLCRDEPTH
WhentheLCRtechniqueisappliedtoanapplicationwith
limited wall thickness, the depth of the LCR wave
penetration is expected to be a function of frequency,
withthelowfrequenciespenetratingdeeperthanthehigh
frequencies.Since,thereisnotareliableequationforthe
relation of LCR depth and frequency and it should be
measuredexperimentally.Fourdifferentfrequencieshave
been used in this work to evaluate the residual stress
through the thickness of the plates. Therefore depth of
anyfrequenciescanbeexactlymeasured.Thesetupwhich
isshowninFig.4isusedheretomeasurethedepthofthe
LCRwave.
Fig.5TensiletesttoevaluateacoustoelasticconstantL11
Fig.4ExperimentalsetuptomeasuredepthofLcrwave
Two transducers as sender and receiver with the same

frequency are used to produce the LCR wave. A slot is
performedbetweenthetransducersbymillingtooltocut
the LCR wave. The depth of the slot is increased step by
step and the amplitude of the LCR wave is measured in
eachstep.WhentheamplitudeoftheLCRwaveisequalto
thenoise,millingprocessisstoppedandthedepthofslot
represents depth of the LCR waves for the tested
frequency. The material used here is the same as the
welded plates. The results of these measurements are
showninTable1.Fromthistableitcanbeconcludedthat
depthsofLCRwaveare5mm,2mm,1.5mmand1mmfor
transducer with nominal frequencies of 1Mhz, 2Mhz,
4Mhzand5Mhzrespectively.
Fig.6 Results of tensile test to evaluate on carbon steel

sample
EVALUATIONOFTHECALIBRATIONCONSTANTS
To evaluate the calibration constants (acoustoelastic
constant, free stress timeofflight), two different
calibration samples were prepared. The first sample was
taken from a stainless steel 304 plate with exactly the
same thickness and chemical composition of stainless
steelsideofthepipes.Thesecondonewasextractedfrom
a carbon steel A106B plate with the same thickness and
chemicalcompositionofcarbonsteelsideofthepipes.To
evaluate the residual stress from Eq.(4), the value t0 is
measured directly from the stressfree samples and the
acoustoelasticconstantisdeducedexperimentallyfroma
uniaxial tensile test associated with an ultrasonic
measurement (Figure 5). Acoustoelastic constant
representstheslopeoftherelativevariationcurveofthe
timeofflightandtheappliedstress,asshowninFigure6
andFigure7.
Fig.7 Results of tensile test to evaluate on stainless steel

sample
RESULTSANDDISCUSSION
In this study, the ultrasonic measurement concerns the
residual stresses through the thickness of dissimilar
welded pipes. 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 zonewere calculated from the equations (14)
and the results are shown in Figure 8Figure 11. The
characteristicsofweldingresidualstressdistributioninthe
pipe are very complex especially for hoop stresses. The
hoop residual stresses distribution which is shown in
76
Y. Javadi
measurement(whichisdonein5mmfromthesurface)is
similartotheaverageoftheinsideandoutsidesurfacesof
the pipes especially more close to the inside surface
distribution. Because, the thickness of the pipes is 8mm
and 1Mhz LCR wave travels more near to the inside
surface. Also, it is obvious from Figure 9, 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
distributionontheoutsidesurfaceofthepipes.Alsoitcan
be concluded from Figure 8Figure 11 that peak of the
residualstressinstainlesssteelsideishigherthancarbon
steelsidebecauseofhigheryieldsstressinstainlesssteel.
Figure 12Figure 13 and has been extracted from D.Deng

[24] is more popular in the references. Figure 12 shows
that, on the inside surface, tensile hoop stresses are
generated at the weld zone and its vicinity, and
compressive stresses are produced away from the weld
centerline[24].ButFigure13showsthedistributionofthe
hoop stress on the outside surface is very complex.[24]
From the simulation and experiment results of D.Deng
[24], it can be found that the shape is like a wave and
very sensitive to the distance from the weld
centerline.[24] Comparing Figure 12 and Figure 13 with
residual stress results of this paper, shows reasonable
agreement. It can be noticed that the results of 1Mhz
Tab.1TheresultsofLcrdepthmeasurement
1Mhz
2Mhz
D
A
T
D
A
0
0.75
0.5
1
0.55
4Mhz
A
5Mhz
A
10.91
0.35
10.58
0.28
10.6
13.09
0.66
13.1
0.5
0.5
10.93
1.5
0.3
10.6
1.5
noise
0.6
13.14
0.42
10.98
noise
1.5
0.54
13.18
1.5
0.4
11.02
0.49
13.21
0.34
11.06
2.5
0.47
13.26
2.5
noise
0.43
13.29
3.5
0.42
13.33
0.4
13.37
4.5
0.33
13.37
0.2
13.37
5.5
noise
*D:DepthofMachining(mm);A:Amplitude;T:TimeofFlight(s)
Fig.10Ultrasonicstressmeasurementresultsby4MHzLCR
wave
Fig.8 Ultrasonic stress measurement results by 1MHz LCR

wave
wave

wave
77
Y. Javadi
Fig.14Ultrasonicstressmeasurementresults
Fig.12 Hoop stress distribution on the inside surface of

pipes(extractedfrom[24])
Fig.15Residualstressontheweldcentreline
CONCLUSIONS
Thispaperconfirmsthepotentialoftheultrasonicresidual
stressmeasurementintheinspectingtheweldingresidual
stressesthroughthethicknessofthedissimilarsteelpipes.
Theresultsofthispapershowthat:
1. Thehoopresidualstressofthepipesisverycomplex
and very sensitive to the distance from the weld
centerlineontheoutsidesurfaceofthepipes.
2. With increasing the frequency (so decreasing the
distancefromthesurface)residualstressdistribution
is became more similar to the hoop stress
distributionontheoutsidesurfaceofthepipes.
3. The peak of residual stress in stainless steel side is
higherthancarbonsteelsidebecauseofhigheryields
stressinstainlesssteel.
4. Ultrasonic is capable of measuring the difference
between residual stresses of two dissimilar pipes in
the points far away from weld centerline. Of course
this difference considerably increases by higher
frequenciesoftransducers.
5. The tensile stress of weld centerline decrease with
increasingthefrequency.
6. Residual stress near the outer surface (higher
frequencies) is more sensitive to the distance from
theweldcenterline.
Fig.13 Hoop stress distribution on the outside surface of

pipes(extractedfrom[24])
The other difference between residual stresses of two
dissimilar pipes is in residual stress distribution in the
pointsfarawayfromweldcenterline.Thatis becauseof
difference in the thermal conductivity constant between
stainlesssteelandcarbonsteel.Ofcoursethisdifference
considerably increases by higher frequencies of
transducers. To better compare of this difference, all of
thefrequenciesareshowninFigure14.Generally,higher
thermal conductivity of carbon steel causes to tensile
stressinthiszoneandcompressivestressforthestainless
steel side. This manner can be observed in Figure 8 but,
abouttheotherfrequenciesthereiscompressivestressin
the carbon steel side too, which is probably because of
complex distribution of outside hoop stresses. Residual
stressexactlyontheweldcenterlineisshowninFigure15.
It can be noticed that tensile stress of weld centerline
decreasewithincreasingthefrequency.Also,itisobvious
fromthisfigurethatresidualstressneartheoutersurface
(higherfrequencies)ismoresensitivetothedistancefrom
the weld centerline. Therefore the ultrasonic residual
stress measurement used in this paper, is capable of
inspecting the welding residual stresses through the
thicknessofthestainlesssteelpipes.
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[17] D.M. Egle, D.E. Bray, Measurement of acoustoelastic
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D.E.Bray,J.F.Cook,C.D.Colwfer,D.M.Schlader(Eds.)
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SanDiego,CA,June2327,1991,pp.3944.
[22] K.J. Langenberg, P. Fellenger, R. Marklein, On the
nature of the socalled subsurface longitudinal wave
and/or thesurface longitudinal 'creeping' wave, Res.
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NuclearEngineeringandDesign,207(2001),pp. 231
240.
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simulationoftemperaturefieldandresidualstressin
multipass welds in stainlesssteel pipe and
comparisonwith
experimental
measurements,
ComputationalMaterialsScience,2005
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11091119
79
Y. Javadi

TheProceedings
Measurement of Through Thickness Residual Stresses in Stainless

Steel Welded Plate Using Ultrasonic Longitudinal Waves
YasharJavadiAlirezaBahman
1
DepartmentofMechanicalEngineering,IslamicAzadUniversitySemnanBranch,Semnan,Iran,Email:yasharejavadi@yahoo.com
DepartmentofMechanicalEngineering,IslamicAzadUniversitySemnanBranch,Semnan,Iran,Email:bahman_alireza@yahoo.com
ARTICLEINFO:
Abstract:
UltrasonicStressMeasurement
AcoustoelasticEffect
WeldingResidualStress
LCR
Ultrasonic stress measurement is based on acoustoelasticity, i. e. the relationship of stress and wave velocity in
engineering materials. This technique uses critically refracted longitudinal waves that travel parallel to the surface, i.
e. LCR waves. The longitudinal critically refracted (LCR) wave is a bulk longitudinal mode that travels within an
effective depth underneath the surface. This paper evaluates welding residual stresses in plate-plate joint of AISI
stainless steel 304L. Because of the residual stress changing through the thickness, the accurate depth underneath
the surface in LCR waves is measured for 1Mhz, 2Mhz, 4Mhz and 5Mhz transducers. After the accurate
measurement of depth, residual stresses through the thickness of plates are evaluated by four different series of
transducers. It has been shown that the residual stresses through the thickness of stainless steel plates can be
inspected by LCR waves.
Citation: Javadi,Y.,Bahman,A. MeasurementofThroughThicknessResidualStressesinStainlessSteelWeldedPlateUsingUltrasonicLongitudinalWaves,2ndInternationalConference

INTRODUCTION
Residual stresses are present in materials without any
external pressure, and normally result from deformation
heterogeneitiesappearinginthematerial.Theyhavevery
important role in the strength and service life of
structures. Welding is an assembly process often used in
different industries, especially in the pressure vessel
industry. According to the process and temperatures
reached during this operation, dangerous thermo
mechanicalstressesmayappearinandaroundthewelded
joint.Toachieveaproperdesignofstructureandcontrol
theirmechanicalstrengthinservice,itisveryimportantto
determinetheresidualstresslevelswithanondestructive
method. Rising demand of industry for the stress
measurement techniques encouraged development of
several methods like Xray diffraction, incremental hole
drilling, and the ultrasonic waves methods. Many studies
showedthatthereisnouniversalorabsolutemethodthat
gives complete satisfaction in the nondestructive stress
monitoring of the mechanical components. Many
parameters such as material, geometry, surface quality,
cost, and accuracy of the measurement, etc., must be
taken into account in choosing an adequate technique.
The ultrasonic technique was selected for stress
measurement because it is nondestructive, easy to use,
andrelativelyinexpensive.However,itisslightlysensitive
to themicrostructure effects (grains size [1, 2, 3], carbon
rate[4,5],texture[6,7,8,9],andstructure[10,11,12])
and to the operating conditions (temperature [13, 14],
coupling [15, 16], etc.). The ultrasonic estimation of the
residual stresses requires separation between the
microstructureandtheacoustoelasticeffects.
alsocalledsurfaceskimminglongitudinalwaves(SSLW)by
someoftheauthors.Brekhovskii[Error!Referencesource
not found.19], Basatskaya and Ermolov [20Error!
Reference source not found.], Junghans and Bray [21],
Langenbergetal.[Error!Referencesourcenotfound.22]
hadsomedetaileddiscussionsonthecharacteristicsofthe
LCR.
Fig.1LCRprobeforPMMA(Plexiglas)wedgeonsteel
Ultrasonic stress measurement techniques are based on

therelationshipofwavespeedindifferentdirectionswith
stress.Fig.2showselementsofabarundertensionwhere
the ultrasonic wave propagates in three perpendicular
directions. 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. In Fig. 2a the wave propagates parallel to the
loadandV11representsthevelocityoftheparticlesinthe
same direction (longitudinal wave), meanwhile V12 and
V13 represents the velocity in a perpendicular plane
(shearwaves).
In Fig. 2b and Fig. 2c the waves propagating in the other
directionsandthevelocitiesareshown.TheV22velocityis
THEORETICALBACKGROUND
Within the elastic limit, the ultrasonic stress evaluating
technique relies on a linear relationship between the
stress and the travel time change, i.e. the acoustoelastic
effect [17, 18]. The LCR technique uses a special
longitudinal bulk wave mode, as shown in Fig.1 , which
travels parallel to the surface, particularly propagating
beneaththesurfaceatacertaindepth.TheLCRwavesare
80
Measurement of Through Thickness Residual Stresses in Stainless Steel Welded Plate Using Ultrasonic Longitudinal Waves
Y. Javadi, A. Bahman
The values of acoustoelastic constants for the other

directionscanbeobtainedinthesameway.Thevariation
inthev11velocity,controlledbythecoefficientL11,ismuch
greater than the other ones, indicating that these waves
arethebestcandidatestobeusedinthestressevaluation.
Stress can be calculated by the onedimensional
application of the stressstrain relations in elastic solids.
Eq. (3) can be rearranged to give the stress variation in
termstimeofflight(dt/to),asshownintheEq.(4),where
toisthetimeforthewavetogothroughastressfreepath
inthematerialbeinginvestigated.
for longitudinal waves propagating perpendicular to the

stress direction. The sensitivity of these waves to the
strainhasbeenestablishedbyEgleandBray[17]intensile
and compressive load tests for a bar of rail steel. The
waves with particle motion in the direction of the stress
fieldsshowedthegreatestsensitivitytostress,andthose
with particle motions perpendicular to the stress field
showed the least. The most considerable variation in
travel time with the strain was found for longitudinal
waves, followed by the shear waves when the particles
vibrate in the direction of the load. The other waves do
notshowsignificantsensitivitytothestrain.
E ( dV11 / V11 )
E
dt
L11
L11 t 0
(4)
where d is the stress variation (MPa) and E is the

elasticitymodulus(MPa).Thesameequationcanbeused
for the other directions of the waves, provided the value
of the acoustoelastic coefficient L is changed. For a fixed
probe distance, the travel time of the longitudinal wave
decreasesinacompressivestressfieldandincreasesina
tensile field. The acoustoelastic constant (L) functionally
linksthestressandthevelocityortraveltimechange.
EXPERIMENTALPROCEDURES
The materials tested (A240TP304L) are commonly used
for pressure vessel applications. Single pass buttweld
joint geometry with a backweld pass and without root
gap was used. Two 600*250*10 mm normalized A240
TP304L rolled plates were welded in Vgroove (90
included angle). Backweld and the main weldpass were
performedbysubmergedarcwelding(SAW)process.Two
rectangular tension test specimens were extracted from
PM (Parent Material) to determine acoustoelastic
constant. The measurement device, shown in Fig.3,
includes an ultrasonic box with integrated pulser and
receiver, computer and three normal transducers
assembled on an integrated wedge. A threeprobe
arrangementwasused,withonesenderandtworeceivers
in order to eliminate environment temperature effect to
the travel time. Twelve transducers in four different
frequencies were used where their nominal frequencies
were 1Mhz, 2Mhz, 4Mhz and 5Mhz. Using different
frequencies helps to evaluate residual stresses through
the thickness of the plates. The diameter of all the
piezoelectric elements was 6 mm. Transducers were
assembledonanintegratedPMMAwedge.Theultrasonic
box is a 100Mhz ultrasonic testing device which has a
synchronizationbetweenthepulsersignalandtheinternal
clock, that controls the A/D converter. This allows very
precise measurements of the time of flight better than
1ns.
Fig.2Velocityofplanewaveandstressfieldinorthogonal
directions[23]
The velocities of the longitudinal plane waves traveling
parallel to load can be related to the strain () by the
followingexpressions:
0V112 2 (2l ) (4m 4 10)1 (1)
whereoistheinitialdensity;V11isthevelocityofwaves
in the direction 1 with particle displacement in the
direction1;,thesecondorderelasticconstants(Lames
constants); l, m, n are the third order elastic constants;
1 2 3 which1,2and3arecomponentsofthe
homogeneous triaxial principal strains. For a state of
uniaxialstress,1=,2=3=,whereisthestrain
inthedirection1andisthePoissonsratio.Usingthese
values,Eq.(1)becomes:
0V112 2 [4( 2 ) 2( 2m) (1
)]. (2)
Therelativesensitivityisthevariationofthevelocitywith
the strain and can be calculated by Eq. (3). In this
equation,L11isthedimensionlessacoustoelasticconstant
forLCRwaves.
dV11 / V11
( 2m) v (1 2l / )
2
L11 (3)
d
2
81
the value t0 is measured directly from the stressfree

samples and the acoustoelastic constant is deduced
experimentallyfromauniaxialtensiletestassociatedwith
anultrasonicmeasurement(Fig.5andFig.6).Krepresents
the slope of the relative variation curve of the timeof
flightasdescribedbyEq.(5).
Fig.3Measurementdevices
WhentheLCRtechniqueisappliedtoanapplicationwith
limited wall thickness, the depth of the LCR wave
penetration is expected to be a function of frequency,
withthelowfrequenciespenetratingdeeperthanthehigh
frequencies.Since,thereisnotareliableequationforthe
relation of LCR depth and frequency and it should be
measuredexperimentally.Fourdifferentfrequencieshave
been used in this work to evaluate the residual stress
through the thickness of the plates. Therefore depth of
anyfrequenciescanbeexactlymeasured.Thesetupwhich
isshowninFig.4isusedheretomeasurethedepthofthe
LCRwave.
(5)
Fig.5TensiletesttoevaluateacoustoelasticconstantL11
Fig.4ExperimentalsetuptomeasuredepthofLcrwave
Two transducers as sender and receiver with the same

frequency are used to produce the LCR wave. A slot is
performedbetweenthetransducersbymillingtooltocut
the LCR wave. The depth of the slot is increased step by
step and the amplitude of the LCR wave is measured in
eachstep.WhentheamplitudeoftheLCRwaveisequalto
thenoise,millingprocessisstoppedandthedepthofslot
represents depth of the LCR waves for the tested
frequency. The material used here is the same as the
welded plates. The results of these measurements are
showninTable1.Fromthistableitcanbeconcludedthat
depthsofLCRwaveare5mm,2mm,1.5mmand1mmfor
transducer with nominal frequencies of 1Mhz, 2Mhz,
4Mhzand5Mhzrespectively.
Fig.6 Results of tensile test to evaluate acoustoelastic

constant
EVALUATIONOFTHECALIBRATIONCONSTANTS
In this study, the ultrasonic measurements were used to

determine the residual stresses through the thickness of
welded plates. The measurements were parallel to the
weld axis. The values of the residual stresses relating to
each weld zonewere calculated from the equations (14)
and the results are shown in Fig.710. Fig.710 show that
tensile residual stresses are generated at the weld zone
To evaluate the calibration constants (acoustoelastic

constant, free stress timeofflight), the calibration
samples were taken from both sides of the plates. Two
rectangular tension test specimens were extracted to
determine acoustoelastic constant (L11) with average of
the results. To evaluate the residual stress from Eq. (4),
82
t0
InEq.(5)istheappliedstress,tandt0arethetimeof
flight measured between the two receivers for stressed
and unstressed samples, respectively. The acoustoelastic
constant(L11)isequalto(KE),whereKiscalculatedfrom
Eq.(5)andEistheelasticitymodulus.
DETERMINATIONOFLCRDEPTH
(t t0 )
main weldpass. It can be noticed that this frequency

shows the minimum level of residual stresses probably
becauseofminimumwidthofmeltedzoneinthislocation.
Ofcourse,theresidualstressonthesurfaceisthehighest
whichiswellshownintheFig.10.Thereforetheultrasonic
residualstressmeasurementusedinthispaper,iscapable
of inspecting the welding residual stresses through the
thicknessofthestainlesssteelplates.
and its vicinity, and compressive stresses are produced

away from the weld centerline. This result is in a good
agreement with the welding theory. Also, it can be
concludedtheresidualstresseshavebeendecreasedwith
increasing of the measurement frequencies. It can be
justifiedthatlowfrequencywavestraveldeeperthanthe
high frequencies therefore inspect bulk residual stresses.
For example, 1Mhz LCR wave (Fig.7) travels in 5mm from
thesurfacewhichisapproximatelythroughtherootofthe
Tab.1TheresultsofLcrdepthmeasurement
1Mhz
2Mhz
D
A
T
D
A
0
0.75
0.5
1
0.55
4Mhz
A
5Mhz
A
10.91
0.35
10.58
0.28
10.6
13.09
0.66
13.1
0.5
0.5
10.93
1.5
0.3
10.6
1.5
noise
0.6
13.14
0.42
10.98
noise
1.5
0.54
13.18
1.5
0.4
11.02
0.49
13.21
0.34
11.06
2.5
0.47
13.26
2.5
noise
0.43
13.29
3.5
0.42
13.33
0.4
13.37
4.5
0.33
13.37
0.2
13.37
5.5
noise
*D:DepthofMachining(mm);A:Amplitude;T:TimeofFlight(s)

wave

wave

wave
wave
CONCLUSIONS
Thispaperconfirmsthepotentialoftheultrasonicmethod
in measurement of the welding residual stresses through
the thickness of the stainless steel plate. It has been
shownthattheresidualstressconsiderablydecreasewith
increasing the depth of measurement where the lower
frequency waves can penetrate. Since the ultrasonic
83
[12] JH.
Cantrell,
K.
Salama,
Acoustoelastic
characterization of materials, Int Mater Rev,
36(1991),pp.125145.
[13] K. Salama, Relationship between temperature
dependence of ultrasonic velocity and stress,
Quantitative nondestructive evaluation, 1985, pp.
11091119
[14] H. Mohbacher, E. Schneider, K. Goebbels,
Temperature dependence of thirdorder elastic
constants, Proc 9th international conference on
experimentalmechanics,3(1990),pp.11891197.
[15] DI. Crecraft, The measurement of applied and
residual stresses in metals using ultrasonic waves, J
SoundVib.,5(1967),pp.173192.
[16] A. Lhmery, P. Calmon, S. Chatillon, N. Gengembre,
Modeling of ultrasonic fields radiated by contact
transducer in a component of irregular surface,
Ultrasonics,40(2002),pp.231236.
[17] D.M. Egle, D.E. Bray, Measurement of acoustoelastic
and third order elastic constants for rail steel, J.
Acoust.Soc.Am,60(1976),pp.741744.
[18] D.E. Bray, R.K. Stanley, Nondestructive Evaluation,
CRCPress,BocaRaton,FLrevisededition,1997.
[19] L.M.Brekhovskii,WavesinLayeredMedia,Academic
Press,1(1960).
[20] L.V. Basatskaya, I.N. Ermolov, Theoretical study of
ultrasonic longitudinal subsurface waves in solid
media,J.Ultrasonics,27(1980),pp.226233.
[21] Junghans,P.,Bray,D.E.,Beamcharacteristicsofhigh
angle longitudinal wave probes. In: R.N. Pangbom,
D.E.Bray,J.F.Cook,C.D.Colwfer,D.M.Schlader(Eds.)
NDE: Applications, Advanced Methods, and Codes
andStandards,PVPVol.216,NDEVol.9,Proceedings
1991 ASME Pressure Vessels and Piping Conference,
SanDiego,CA,June2327,1991,pp.3944.
[22] K.J. Langenberg, P. Fellenger, R. Marklein, On the
nature of the socalled subsurface longitudinal wave
and/or thesurface longitudinal 'creeping' wave, Res.
Nondest.Eval.,2(1990),pp.5981.
[23] D.E. Bray, W. Tang, Evaluation of Stress Gradients in
Steel Plates and Bars with the LCR Ultrasonic Wave,
NuclearEngineeringandDesign,207(2001),pp. 231
240.
inspection is performed nondestructively, there is no

damageonthestainlesssteelplateafterstressmeasuring
process.
REFERENCES
[1] N.Grayli,JC.Shyne,Effectofmicrostructureandprior
austenite grain size on acoustic velocity and
attenuation in steel, Rev Prog NDE, 4(B)(1985), pp.
927936.
[2] R. Herzer, E. Schneider, Instrument for the
automated ultrasonic timeofflight measurement a
tool for materials characterization, Springer, 1989,
pp.673680.
[3] P. Palanchamy, A. Joseph, T. Jayakumar, Ultrasonic
velocitymeasurementsforestimationofgrainsizein
austenitic stainless steel, NDT E Int, 28(1995), pp.
179185.
[4] EP. Papadakis, Physical acoustics and microstructure
ofironalloys,IntMaterRev,29(1984),pp.124.
[5] C. Hakan Gr, B. Orkun Tuncer, Nondestructive
investigation of the effect of quenching and
tempering on mediumcarbon low alloy steels, Int J
MicrostructMaterProp,1(2005),pp.5160.
[6] MA.Ploix,R.ElGuerjouma,J.Moysan,G.Corneloup,
B. Chassignole, Acoustical characterization of
austenitic stainlesssteel welds for experimental and
modeling,NDT.JSocAdvSci,17(2005),pp.7681.
[7] M. Spies, E. Schneider, Nondestructive analysis of
textureinrolledsheetsbyultrasonictechniques,Text
Microstruct,12(1990),pp.219213.
[8] GC. Johnson, Acoustoelastic response of a
polycrystalline aggregate with orthotropic texture, J
ApplMech,52(1985),pp.659663.
[9] CM. Sayers, Ultrasonic velocities in anisotropic
polycrystalline aggregates, J Phys D Appl Phys,
15(1982),pp.21572167.
[10] C. Hakan Gr, ?. am, Comparison of magnetic
Barkhausen noise and ultrasonic velocity
measurements for microstructure evaluation of SAE
1040 and SAE 4140 steels, Materials Charact,
58(2007),pp.447454C.
[11] YH. Nam, YI. Kim, SH. Nahm, Evaluation of fracture
appearance transition temperature to forged 3Cr
1Mo0.25 V steel using ultrasonic characteristics,
MaterLett.,60(2006),pp.35773581.
84

TheProceedings
Tribological Features of Journal Bearings Made of Bimetallic Alloy

MilanKadnr1JurajRusnk1JanValek2,3MilenaKunerov2,3PavolTkly4
1
FacultyofEngineering,SlovakUniversityofAgricultureinNitra,Slovakia
FacultyofMiningandGeology,VBTechnicalUniversityofOstrava,CzechRepublic
FacultyofMetallurgyandMaterialsEngineering,VBTechnicalUniversityofOstrava,CzechRepublic
4
FacultyofSpecialTechniques,AlexanderDubekUniversityofTrenn,Slovakia
2
3
ARTICLEINFO:
Abstract:
Bimetallicalloy
Journalbearings
tribologicalexperiment
TribotestorM06
Thecompetitiveenvironmentforcesproducersinautomotiveindustrytodecreasethecosts.Producersas
well as subsuppliers need to find possible savings. The paper presents results of laboratory experiments
with real journal bearings made of bimetallic alloy realised to find out possible replacement of a rolling
bearingbyajournalbearing.Theimportantcorrelationbetweenresultsoflaboratoryexperimentswitha
model of tribological system and the real journal node may by achieved by maximum approach of
simulation features by real running conditions. Thus, the given experiment conditions result from the
chosen application, i.e. steering servo unit. The experiments were realised on Tribotestor M06 testing
machine.
Citation:KadnrM.,etal.TribologicalFeaturesofJournalBearingsmadeofBimetallicAlloy,2ndInternationalConferenceManufacturingEngineering&Management2012,(2012),p.85
88,ISBN9788055312163
INTRODUCTION
Nowadays, the experimental determining of tribological
features is realised via devices with different
configurations. It is very common that the experiment
parameters are always chosen based on the needs and
demands. Each experiment is influenced by several
factors, whereas the weight of factors is different and
each of them is determined to solve a partial tribological
task [9], [1], [11], [7]. The data reached from the
experiments have important influence for interpreting
results where friction and wear are measured. The
development of microtribology and nanotribology
influencestheparametersofexperimentaltestingdevices.
There is a trend of using devices with low surface speed
and loading on few Newtons. In most situations, the real
friction node is replaced by a line contact or a spot
contact, however the reached friction coefficient cannot
be compared with values of real journal nodes [3], [6],
[10]. 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], [8], [5]. According to
the simple design of existing devices, the minimum
possibility of changing the parameters during the
experimentmaybeseenastheirdisadvantage.
Fig.1ThediagramofTribotestorM06testingmachine
Thefrictioncoefficientisdeterminedbytheformula:
Ft .a
(1)
Thus,thefrictioncoefficientdependson:
theforceontheendoftestingheadsarmFt,N,
thelengthoftestingheadsarma,mm,
thenormalforceFN,N,
theradius(diameter)ofatestingshaftrH,mm.
MATERIALANDMETHODS
TestRig
InexperimentswithrealsjournalbearingstheTribotestor
M06testingmachineallows:
tousethemostmodernmeasuringtechnology,
toinfluencetherangeofrunningparameters,
toprovidemodificationeasily,
toprovideseverallubricationmodes,etc.
WhenajournalnodeisloadedbynormalforceFN,thereis
a friction between shaft and bearing, represented by
frictionforceFTeffectingrotationmovementoftheshaft.
The friction also causes the transmission of torsion
moment to the head of testing machine (Fig. 1). The
transmittedtorsionmomentisdefinedbyfrictionforce
FT=FTandradius(diameter)oftheshaftrH.
MATERIAL
Fortheproducerofasteeringservounit,theexperiments
with different kinds of journal bearings were elaborated
forthepurposeofreplacingarollingbearingbyajournal
bearing. The reason of the purpose was an expected
saving. Bimetallic bearings are made by curling bimetallic
strips with different sliding materials. 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.Thesmoothstructureisconsideredtobethemain
advantage because the bearings of these materials are
usablealsowithinthecriticalfriction.Thestructureofthe
materialsisillustratedinTable1.
85
FN .rH
M. Kadnr et al.
Tribological Features of Journal Bearings made of Bimetallic Alloy
was used rather than surface speed concerning the

featuresofsteeringservounit.
Tab.1Chemicalstructureofmaterials(weightpercentage)
Material
Cu Pb Sn Zn P
Fe Ni Sb Others
B10
9
rest
911 0.5 0.1 0.7 0.5 0.2 0.5
CuPb10Sn10
11
B30
26
rest
0.5 0.5 0.1 0.7 0.5 0.2 0.5
CuPb30
33
Tab.3Phasesoftheexperimentforfrictionmeasurement
Phase
Slidingnode
stabilisation
B10 material is a metalpolymer composite material with

excellent friction features also without lubrication. The
requiredshaftroughnesscannotexceed0.4m,theshaft
hardnessmustbeover200HB.B30isabimetallicmaterial
with bronze alloy. The required shaft features are the
same as for B10 material. The basic features of B10 and
B30materialsareillustratedinTable2.
Tab.2BasicfeaturesofB10andB30materials
Materia
l
B10
B30
Chemical
structure
CuPb10Sn1
0
CuPb30
Tensile
strengt
h/MPa
Maximum
loadin
static
stress/MP
a
Maximum
loadin
dynamic
stress/MP
a
Maximum
operation
temperatur
e/C
230280
200
120
250
90107
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
withconstant
speed
520
120
150
4000
640
120
150
500
Supporting
measurement
forchecking
ofmeasuring
device
760
30
100
790
30
150
820
30
200
850
30
250
Slidingnode
stabilisation
EXPERIMENTS
The following conditions were followed during the

experimentsforfrictionmeasurement:
shaft of 10, cemented, hardened and edged
material SN 14 220 (each shaft used only for one
measurement),
bearingclearanceof0.02mm,
sixtestedsamplesofeachmaterials,
nolubrication.
KADNR (2009) illustrates the selection of experiment
parameters.Basedontheparameters,thecomplexmode
of the experiment for friction measurement was
determined. The mode included several partial phases
which are illustrated in Table 3. Before the experiment
each sliding node was exposed by test run of 600 s with
revolutions of 2000 min1 and load of 150 N. The phase
was considered to be a preparatory phase and the
reached results are not taken into consideration further.
Afterthetestruneachnodewasstabilised,i.e.loadedby
20 N with revolutions of 2000 min1. Consequently, the
measurementwithrevolutionsof2000min1wasrealised
with load of 100 N, 150 N, 200 N and 250 N. Each
measurement lasted 120 s. Before measurement with
constant load each node undertook another stabilisation
whichlasted20sloadedby20Nwithrevolutionsof4000
min1. The measurement with constant load was
undertaken with load of 150 N and revolution of 4000
min1or500min1.Thebothmeasurementslasted120s.
The diagram of load and rotational frequency depending
on time is illustrated in Fig. 2. There are many statistical
interpretations of friction measurement. For an
application in tribology, the table data is used rather as
additional information [1], [2], [4], [12]. The most
important information is that in the unfiltered record
during friction force measurement. Generally, the
measured data reflects the reality in a tribological node.
Furtherprocessedinformationinatableorafigureisonly
its interpretation. Thus, we have decided for a
compromise, i.e. for a figure interpretation with
illustrating average value of measurement and statistical
intervalof95%.Theideaissupportedbythefactthatthe
total friction coefficient is not a measured value but a
calculatedone.Atthesametime,therotationalfrequency
Load/N
300
200
100
Revolutions/rpm
200
400
600
800
1000
Time/s
4000
3000
2000
1000
0
0
200
400
600
800
1000
Time/s
Fig.2Loadandrotationalfrequencydependingontime
Within a sliding node B10 material had stable features in
connection with the variable load or variable rotational
frequency.Noimportantvibrationswererecordedduring
test run and experiments themselves. The diagram of
friction coefficient within constant rotational frequency,
i.e.dependingonvariableloadisillustratedinFig.3.
Fig.3B10materialfrictioncoefficientdependingonload
86
Measurement
withconstant
speed
Time/s Duration/s Load/N Revolutions/rpm
M.Kadnr, et al.
At the load of 100 N, the friction coefficient was 0.05.

When decreasing the load, there were only little
differences of friction coefficient. The temperature was
practically the same, i.e. 42 C. At the load of 250 N, the
frictioncoefficientwas0.05.Thus,theslidingnodeofB10
materialcanbeevaluatedtobefavourable.Attheloadof
150 N there was only a little decrease of friction
coefficient. At the rotational frequency of 500 min1 the
lubrication mode can be considered to be mixed.
However, the friction coefficient did not exceed the limit
of 0.1. During the experiment the friction coefficient
ranged from 0.06 to 0.07. The diagram of friction
coefficient with constant load and variable rotational
frequencyisillustratedinFig.4.
Regarding the surface of journal bearing of B10 material,

the separation of surface was recorded. In some parts
there was a visible subsurface layer of sintered bronze.
Based on the results the wear resistance of B10 material
towards the chosen application is not sufficient. The
weight loss of B10 material ranged from 9 to 14 mg (Fig.
6).
The test run or experiments themselves when using B30
material recorded more important vibrations. Fig. 7
illustratesthediagramoffrictioncoefficientdependingon
variable load. At the load from 100 to 200 N the friction
coefficient was 0.08. At the load of 250 N the friction
coefficient decreased to 0.07. The temperature was not
more than 43 C. At the load of 150 N and lower
frequencies the friction coefficient decreased to 0.10. It
resulted from conditions in sliding node which
correspondstotheareaofmixedfriction.Thediagramof
friction coefficient with constant load and variable
frequencyisillustratedinFig.8.Atthefrequencyof4000
min1thefrictioncoefficientdecreasedto0.08.
Fig.4 B10 material friction coefficient depending on

rotationalfrequency
1
At the frequency of 4000 min the friction coefficient

decreasedto0.05.Thus,itispossibletoconcludethatthe
sliding node of B10 material is considered to have stable
features. Despite the conclusion, the bearing surface had
little wear, local wear of thin film, i.e. sliding layer on a
surfaceofthematerial(Fig.5).
Fig.5 B10 material surface before (a) and after (b) the
measurement
measurement
measurement
AccordingtothehighvalueoffrictioncoefficienttheB30
materialisconsideredtobelessfavourable.Thesurfaceof
87
M. Kadnr et al.
slidingmaterialhadlocalwear(Fig.9).Thehigherrateof
noiseandvibrationswerealsorecorded.Theslidingnode
hadonlyaveragefeaturesregardingfrictionandwearand
thereforethebearingsafterthetestcanbeconsideredto
be damaged. Based on the experiment results the wear
resistanceofB30materialisevaluatedtobenotsufficient.
REFERENCES
[1] BAYER G. R., 2004. Mechanical Wear Fundamentals
andTesting.NewYork:MarcelDekkerm:399.
[2] BHUSHAN B., 2002. Introduction to Tribology. New
York:JohnWiley&Sons:752.
[3] JOBBGY J. et al., 2003. The pressure states in
hydraulic of tractor ZTS in set agricultural
implements. In: International Student's Scientifics
Conference, April 12. 2003. Nitra, Slovak University
ofAgriculture:94101.
[4] KADNRM.etal.,2009.SelectionofSlidingNodefor
Steering Servo Unit. In: 50th International Scientific
Conference of Departments of Machine Design.
ilina,EDIS.
[5] KADNRM.et al.,2011.TheDesignandVerification
of Experimental Machine for Real Journal Bearing
Testing.Technikivjestnik,18:9598.
[6] KUERA M. 2008. Prediction of Characteristics for
Pairs of Materials in Condition of Limit Friction. Acta
TechnologicaAgriculturae,11:1115.
[7] KUERA M., PRAN J., 2008. Analysis of Friction
Marks and Wear Products. Acta Technologica
Agriculturae,11:4349.
[8] KUERA M., PRAN J., 2008. Tribologic properties of
SelectedMaterials.TechnicalSciences,11228241.
[9] MANG T., DRESEL W., 2001. Lubricants and
Lubrication.NewYork,Wiley:790.
[10] IAIK A., BRONEK J., IKA V., 1995. The Sliding
Properties of the Bearings with Polymer Lining. In:
Faculty of Mechanical Engineering. 2nd Scientific
Conference.ilina:Universityofilina:4044.
[11] NL S. B., ATIK E., 2007. Determination of Friction
Coefficient in Journal Bearings. Materials & Design,
28:973977.
[12] NL S. B., ATIK E., 2009. Tribological Properties of
Journal Bearings Manufactured from Particle
Reinforced Al Composites. Materials & Design, 30:
13811385.
Fig.10B30materialweightloss
TheweightlosswithinB30materialrangedfrom11to16
mg(Fig.10).Astheliteratureconfirms,withindryfriction
the high values of friction coefficient were recorded. The
testedbearingswerestabledependingonloadaswellas
frequency.Forthechosenapplicationthetestedbearings
are considered not to be suitable. In the future it is
possible to verify tribological features of tested bearings
also within hydrodynamic friction, whereas the structure
of testing head allows the circulation of lubricant and
additional influence of sliding node temperature what
helpstosimulaterealconditionsbetter.
ACKNOWLEDGEMENTS
The work has been supported by projects VEGA
1/1064/11, RMTVC No. CZ.1.05/2.1.00/01.0040 and ICT
No.CZ.1.05/2.1.00/03.0082..
88

TheProceedings
Multimedia Support in Subject Material Science

JiKejvalPetrHenc2MiroslavMller3PetrChocholou4
1
DepartmentofMaterialScienceandManufacturingTechnology,CzechUniversityofLifeSciences,Prague,CzechRepublic,kejval@tf.czu.cz
DepartmentofMaterialScienceandManufacturingTechnology,CzechUniversityofLifeSciences,Prague,CzechRepublic,henc@tf.czu.cz
DepartmentofMaterialScienceandManufacturingTechnology,CzechUniversityofLifeSciences,Prague,CzechRepublic,muller@tf.czu.cz
4
DepartmentofMaterialScienceandManufacturingTechnology,CzechUniversityofLifeSciences,Prague,CzechRepublic,chocholousp@tf.czu.cz
2
3
ARTICLEINFO:
Abstract:
Education
Innovation
Teaching
Learning
Multimedia
Article deals about innovation in subject Material Science. Innovation consists of creation multimedia teaching
materials and facility to improve theoretical and practical part of seminars. Due to requirements of current labor
market it is necessary not only theoretical teaching students but also quality practical training during seminars. Due
to small capacity of the laboratory, students can not be fully introduced with a number of material tests that can be
perform at Department of Materials and Manufacturing Technology. Created multimedia facility consisting of
multimedia system and projection equipment will help students thoroughly acquainted with these material tests.
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.
Citation:KejvalJ.,etal.:MultimediaSupportinSubjectMaterialScience,2ndInternationalConferenceManufacturingEngineering&Management2012,(2012),p.8990,ISBN97880
55312163
INTRODUCTION
examples of material tests. 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),
Technological equipment of constructions (code
3647R021), Road transportation and city traffic (code
3708R020), Trade and Business Dealing with Machinery
(code 6208R065), Information and Control Technology in
Agrofood Complex (code 4101R022), Agriculture (code
4101R012) or Engineering maintenance (code 4101R003)
on Technical Faculty at CULS Prague. Therefore, target
group is about 600 students in regular and combined
forms of study. Using multimedia system (video camera,
electronic eyepiece microscope connected to computer)
werefilmedteachingvideosselectedmaterialtestswhich
were subsequently implemented in teaching materials.
Multimedia data for students are also available via e
learning platform Moodle (http://moodle.czu.cz) where it
can be replay anytime. Video tutorials familiarized
students with tests of plastics and metal materials and
alsowiththeirheattreatment.Allvideosaredescribedin
great detail to perform various tests including detailed
view on control of testing machines. Videos are also
focused on very detailed view of test specimen. During
testing structure of materials is used multimedia
electronic system connected to the microscope eyepiece,
laptopandprojector.Thissystemallowstoallstudentsget
to know in detail structure of materials and to teachers
helpexplaintheproblem(Fig.1).
Subject Material Science is teaching by Department of

Material Science and Manufacturing Technology. The
course is intended for most students from Technical
faculty at CULS Prague in regular and combined form of
study. The course is teaching in summer semester in
classical form in range of 2 hours lecture and 2 hours
seminarperweek.Currently,attheseminarstudentsare
introducedwithissueonlytheoretically.Studentsarenot
clearly introduced with details of material tests.
Application of multimedia facility increase practical
teachingofstudentsandsimultaneouslyraisestandardsof
teaching in this field. This project has support and
correspondswithstrategicobjectivesinfieldofeducation
(not learning) university. In field of education strengths
areassociatedwiththequalityandrelevanceofeducation
andflexiblyadaptationanddiversificationrangeofstudy.
Strategic objectives in the field of teaching must aim to
strengthen education in CULS Prague. Education is unlike
learning associated with narrowly defined skills. Bachelor
study programs are specialized education leading to
qualification with expertise and technical skills. Authors
[1],[2]madeanalysis,whereauthorsprovideadirectlink
betweensuccessofstudentsintheexamandtheiractive
participation in the lectures and seminars. From above
factitcanbeconcludedthatbetterandimprovedteaching
duringsemesterwillhaveapositiveimpactonsuccessof
studentsduringexams.Thesurveyshowsthatstudentsdo
not clearly understand link between subjects Material
ScienceandManufacturingTechnology,asstated[1],[2].
We can expect that correctly video footage helps to
students find connection between discussed problems in
thosesubjects.Similarbeneficialissueisapplicationvirtual
realitytechnologynotonlyinteachingbutalsoinpractice
training[3].
Specific outcome of the project is creation multimedia
supportforsubjectMaterialScience.Supportisbasedon
curriculum of subject and its subsequent implementation
into teaching. Outcome of the project was to purchase
system that enables interactive production which is
composed of video camera, camera for microscope,
projector and computer. This multimedia system enables
tothestudentslearnallteststhatareinsubjectMaterial
Science discussed theoretically or teaching in larger
groups. Larger teaching groups during seminars do not
METHODS
Aim of the project is to innovate and improve teaching,
deepen practical student knowledge and create
multimedia support for subject Material Science. Support
is based on subject curriculum and its subsequent
implementation into teaching. Solution is using
multimedia support to familiarize students with practical
89
J. Kejval et al.
Multimedia Support in Subject Material Science
allow to all students familiarize practically with the

problem.
Fig.2Usingmultimediasystemduringteaching
CONCLUSIONS
Project "Multimedia support in subject Material Science"

wassupportedbygrantfromMinistryofEducation,Youth
andSports(UniversityDevelopmentFund)No.2419/2012
in area G1 creative work of students on technical fields
and is mainly dedicated to innovation of subject Material
Science.Theinnovationisinmakingeducationvideoswith
selected materials tests. Important innovation is
interactive projection of tested material structures using
projector, laptop and electron eyepiece. This teaching
systemwasimplementedattheendofsummersemester
and students this system evaluated very positively. In
recent years similar multimedia support has not been
implementedinthesubjectMaterialScience.Asbenefitof
projectcanbeconsidered:
improvement of teaching in subject Material
Science,
increase competitiveness of students in labor
market,
significant benefit is the ability to repeat the
issueinalatertime,
increaseofstudentssafety.
Fig.1Usingmultimediasystemduringteaching
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. Tutorials allow observing
duringtestinhighquality,asshowninFig.2.Combination
of camera, microscope and projector will allow
familiarized students with tests requiring magnification
such as microstructure of material and also graphical
description of magnified image. This multimedia system
also allows record images to create learning materials.
Students at the seminar will learn a number of practical
tests which are based on technical standards. For
processing seminar reports students will use current
standardsavailableinprintedformattheseminar.These
standards are purchased through online license.
Purchasing this license was chosen primarily for financial
reason which is very effective because buy of one
standard is approximately 600 CZK. Students are using
standards for processing seminar reports such as SN EN
10 002, SN EN ISO 6508, SN EN ISO 6506, SN EN ISO
6507etc.
Acknowledgement
This paper has been done when solving grant of title
Multimedia support in subject Material Science Nr.
2419/2012.
REFERENCES
[1] Novkov,A.,Broek,M.:Studyofstudentspresence
inlecturesinfluenceontheirexaminationresults.In.:
11thInternationalScientificConferenceEngineering
for Rural Development.Jelgava, Latvia University of
Agriculture, Faculty of Engineering. 2012, p. 650
654.ISSN16915976.
[2] Novkov,A.,Broek,M.:Evaluationofteachingthe
subject Basic Engineering Technologies. In.: 10th
International Scientific Conference Engineering for
Rural Development. Jelgava, Latvia University of
Agriculture, Faculty of Engineering. 2011, p. 542
547.ISSN16913043.
[3] NovkMarcinin, J., Kuzmiakov, M., Brzda, P.:
Augmented Virtual Reality Applications in
ManufacturingPractice,Strojrensktechnologie,vol.
14,no:special,2010,p.203206.ISSN12114162.
90

TheProceedings
High- Strength Fiber in Polyvinyl Butyral Matrix

LuciaKnapkov1JozefHusr1PeterOravec1
1
FacultyofManufacturingTechnologieswithaseatinPreov,TechnicalUniversityofKoice,DepartmentofManufacturingManagement,Bayerova1,Presov,
Slovakia,email:lucia.knapcikova@tuke.sk
ARTICLEINFO:
Abstract:
Fiber
Matrix
Polyvinylbutyral
PulloutTest
Thermoplast
Highstrengthfibersusedinthemanufactureofcompositematerialswiththermoplasticmatrix,currently
represent high boom of development. The paper is focused on the characteristics of the use of aramid,
carbon, and glass fibers in a thermoplastic matrix, consisting of polyvinyl butyral. Individual fibers were
embedded3and5mminthemiddleofthematrix,thensubjectedtoapullouttest.
Citation:KnapkovL,etal.:HighStrengthFiberinPolyvinylbutyralMatrix,2ndInternationalConferenceManufacturingEngineering&Management2012,(2012),p.9193,ISBN 978
8055312163
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.[1,8] Good
adhesion is essential to ensure good offaxis properties,
and good resistance to water. [2,8] A great deal of effort
has gone into ensuring that adhesion is good [3,8] 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. However, the single
fibre pullout test provides one of the most direct
methodsofmeasuringinterfaceparameters.Thispullout
testcanbeusedtoprovidedataonadhesion,coefficient
of friction at the interface, and the normal pressure (this
arises from the shrinkage of the polymer) if the matrix is
stressedwhilethefibreispulledout.[5]However,mostof
thisworkhasbeencarriedouteitheronmodelsystems,or
under conditions which prevented the measurement of
manyoftheimportantinterfaceparameters.Inthefirstof
thisseriesofpapersweshallreexaminethedynamicsof
the pullout process, in order to determine the optimum
conditions needed to obtain reliable values of as many
parameters as possible in the pullout process. [4,6] In
subsequentpaperswelldescribeexperimentsusingthese
conditions.
Thermoplastic materials promise inter alia based on the

currentlydevelopedeffectiveprocessingtechnologiesand
highgainwithlongfibersandtheachievementofabroad
masssuitabilityindustrialapplicationpotential.
Tab.1Fibermechanicalproperties[13]
Fiber
Tensile
Strength[GPa]
Elongation [%]
Density
-3
[g.cm ]
Fiberglass
50
1,5
3,5
2,5
Carbon fiber
150
2,5
1,5
1,8
Aramid fiber
100
2,0
2,0
1,45
Cordenka
833
20
13,0
1,5
MATERIALANDMETHODS
By the measurement will be used next fiber, namely
Cordenka , which is a material with excellent properties.
EspeciallytheverygoodvolumestabilitymakesCordenka
very popular for use in car industry. [5,9,13] With
Cordenkareinforcedcompositeshaveaverygoodbalance
between stiffness and toughness. Cordenka is processed
alsotofabrics whichareused intheautomotiveindustry
as a fabric reinforcement for tires, but also serve as a
reinforcing material in tubes and other industrial
applications.Fibreglassisaceramicmaterialwithaspecial
feature below a transformation region is the toughness
as high (supercooled liquid), that the body is first
converted into another plastic, and finally into a solid
brittlestate.[2,8,13]MainlyservesasaglassformerSiO2
silica.Thegoodmechanicalpropertiesoftheglassfibersis
based on the strong covalent bonds between silicon and
oxygen. By the addition of various metal oxides, the
structure of the network, and thus the properties of the
fiber changed. If higher requirements are placed on the
mechanical properties is the use of carbon fibers is
advantageous.[11]Onthemarketthereareseveraltypes
of carbon fibers such as highstrength ("high tenacity
HAS"), Stiff ("high modulus HM"), highstrain fibers (HS),
and called intermediate modulus (IM), which have a very
high elongation at break (about 2%). at a modulus of
elasticity higher than HT fibers There are also ultrahigh
stiffness fibers (ultra high modulus UHM). Aramid fibers
have, like carbon fibers, a negative coefficient of thermal
expansion in the longitudinal direction, i.e. with heating
shorterandthicker.Theirspecificstrengthanditsmodulus
of elasticity is significantly lower than that of carbon
WORKMOTIVATIONANDPAPERGOAL
It should be inserted into different fiber different
thermoplastic matrix materials. [6] With the samples
prepared to fiber pullout tests are performed. Based on
the measurement results statements about the strength
ofthebondbetweenfiberandmatrixmustbetaken.The
strength parameters of composite materials are
determined in a complex way by the micromechanics at
thefibermatrixinterface.[6,7]Althoughfiberandmatrix
can be fully characterized, a closed treatment of effects,
such as (thermally induced) biases, interfacial energy,
viscoelastic deformation of the matrix and the fiber
matrix friction delaminated areas to the total material is
largely unclear. With fiber pullout tests fibers known to
different wettability and thermoplastics widely differing
elasticity can be obtained experimentally accessible sizes
for qualitative and (semi) quantitative understanding.
91
E-modul [GPa]
L. Knapkov, J. Husr, P. Oravec
Hight- Strength Fiber in Polyvinyl Butyral Matrix
fibers. In conjunction with the positive coefficient of

expansionofthematrixresincanbemanufacturedhighly
dimensionally stable components. Compared to carbon
composites, the compressive strength of aramid fiber
composites is significantly lower[10,13]. Important
materialispolyvinylbutyrale(PVB)[9],whichwasgranted
by SCHIRMBECK (Germany). Polyvinyl butyrale arising
from the recycling of car glas, we used the material in
granular form. The homogenization was with kneading
equipment (BRABENDER, Germany), we achieved the
desired mix needed to create a composite.
Homogenizationofmixtureswasconducted[3]at150C,
duration30min,torsionmomentis181/min,themachine
temperature is 200 C. Figure 1 presented the scheme of
samplepreparationforpress.
MEASUREMENTSANDRESULTS
The pullout tests [6] are carried out using a Zwick Z020
Univesalprfmaschine[12].The
measurement
is
performed in accordance with DIN ISO 5271. [3]
Thereforeitisnecessarytospecifya widthandthickness
of the sample. Since this in the case of individual fiber
bundles by simple measurement is not possible, are
weighed fiber bundles defined length and from the mass
and density of the material is calculated a hypothetical
width or density. Was measured at a test speed of 5
mm/min.Thespeedforthemodulusofelasticityisatleast
1mm/sintherangeof0,05%and0,25%strain.Thegauge
lengthwas100mm.[3]
Tab.2ResultsofFiberinPVBMatrix
Fibre
100mm
Matrix
Fibre
3mminPVB
5mminPVB
max
max
[%] [MPa]
E
Modul
[MPa]
7457
2,25
393,6
15026
95,4
5437
1,22
134,3
8752
Fibreglass
2,45 128,7
4907
3,42
166,8
4430
Cordenka
1,9
2936
6,30
124,0
2117
max max
[%] [MPa]
Emodul
[MPa]
Aramid
Fibre
1,39 228,7
Carbon
Fibre
1,35
63
Onthenextfigureswellseethesampleaferpulltest.The
Figure3showthefibreglassinthethermoplasticpolyvinyl
butyral.Lenghtoffibreis3mminthemiddleofmatrix.
100mm
Fig.1Schemeofsamplepreparation
Measurementconditions
PVBsheetpressing,at125C,2min
Samplecutonthesize2x4cm
Samplepiecescutonthenarrowside
Size3or5mmfromtheedgeofthesamplecheck
Insert the fiberbundle to themark, place specimen
with
fibersothatthefiberslieinthegroovesofthedie
Samplepressfor2min
Forfixingandasclampingaidforthetensiletest,thefiber
The samples are clamped such that the protective carton
withtheedgeofthelowerjawcloses,sothatthefiberis
notdamagedbythejaw(seeFigure2).Thematrixofthe
sample is clamped accordingly so that the zone in which
the fiber is buried is exposed (see Figure 2). End of the
samplearegluedwithepoxyresinoncarton.
90mm
Fig.3FibreglassinPVB
The Figure 4 presented the carbon fibre in the
thermoplaticpolyvinylbutyralalso,butthelenghtis5mm
inthemiddleofmatrix.
3mm
Carton
Fig.4CarbonFibreinPVB
Theseexperimentsshowedthatthepathforthefiberout
of the matrix is relatively wide. Therefore it was decided
to experiment with samples in which the fibers were
inserted just 3mm deep into the matrix, to be repeated.
Theseexperimentsyieldedthefollowingresults.
Matrix
EpoxyResin
Fibre
Fig.2Samplepreparationfortensiletest
92
Hight Strength Fiber in Polyvinyl Butyral Matrix
L. Knapkov, J. Husr, P. Oravec
REFERENCES
[1] Juri, A. et al.: Experimental analysis of the
strength of a polymer produced from recycled
material,In:TechnicalGazette,Vol.18,Nr.4(2011),
627631
[2] Nielsen,E.L.,LandelF.R.:Mechanicsandanalysisof
compositematerials,Elsevier(2001).
[3] DIN Taschenbuch 18, Kunststoffe Mechanische und
thermischeEingeschaften,(1998).
[4] Schuermann,H.:KonstruktierenmitFaserKunststoff,
Verbunden,SpringerBerlin(2001).
[5] Knapkov,L., Herzog,M., Oravec,P.: Manufacturing
EngineeringVol.4(2010).
[6] Knops, M.: The Puck Theory of Failure in Fiber
Polymer Laminates, Fundamentals, Verification and
Applications,SpringerVerlagBerlin(2007).
[7] M.Vable.:Mechanicsofmaterials,[Online].Available:
http://www.me.mtu.edu [Accessed: 19September
2012].
[8] PiggottH.R.,PolymerComposites(1982),p.193
[9] ReifenRecyclingAnlagen[online].Available:
http://www.mewarecycling.de.
[10]V.V.Vasiliev,V.E.Morozov:Mechanicsandanalysis
ofcompositematerials,Elsevier(2001).
[11] V. vork : Structure and properties of polymers,
VCHT,Praha,(2010).
[12] ZWICKZ020,[online].Available:http://
www.zwick.com/.
[13] 50 years of reinforced plastic boats, George Marsh,
(2006),[online].Available:http://www.reinforcedplasti
cs.com/view/1461/50yearsofreinforcedplastic
boats/.
Fig.5ComparisonoffiberinthePVBmatrix
Asexpected,theextractvoltageforthesamplesinwhich
the fibers have a lower contact with the matrix, which is
lowerthanwithalargercontact.
CONCLUSION
With aramid fibers are recorded in matrix material the
highest stresses to failure. The comparison of the fiber
used by polyvinyl butyral matrix show that with aaramid
fiber with 5 mm in the midlle of matrix has a higher
voltages as with carbon fiber. An essential parameter
which single fiber was varied, loading rate, loading
direction,fibertensionandthesurroundingfibrousmatrix
volumeshouldbeinvestigated.Thefibrepulloutprocess
isgovernedbyatleastfivefactors,andusefuldatacanbe
obtained on at least three interface properties, by single
fibre pullout experiments, carried out under carefully
controlled conditions. It is particularly important to keep
thefibreembeddedlengthsmall(<3mm,inourcase)and
thefreelength(thelengthneitherinthegrips norinthe
polymer) less than 3 mm, at least in the case of glass.
Useful data on carbon fibres should be obtainable with
about the same values for free length and embedded
length. Can be say, and its truth, global polymer
production on the scale present today began in the mid
20th century, when low material and productions costs,
newproductiontechnologiesandnewproductcategories
combined to make polymer production economical. Fibre
reinforced plastics have been a significant aspect of this
industry from the beginning. In this paper was presented
three important categories of fibre used in fabric
reinforcedplastic,glass,carbon,aramidandCordenka.
93

TheProceedings
New Manufacturing Technologies in Republic of Croatia

SanjaKneevi1LenaSigurnjak1MiroslavDuspara2
1
UniversityofAppliedSciencesofSlavonskiBrod,Dr.MileBudaka1,35000SlavonskiBrod,Croatia
2
J.J.StrossmayerUniversityofOsijek,MechanicalEngineeringFaculty,TrgI.B.Maurani2a,35000SlavonskiBrod,Croatia
ARTICLEINFO:
Croatia
Enterprises
Industry
Manufacturing
Technologies
Abstract:
Croatian industry is entering a crucial period of its profiling and survival in global market. In the last 15-20 years is
not significant invested in new technology and new product development. Modern enterprises must adopt and
assimilate new technologies to build and sustain competitive advantage. New technologies revolutionize way how
products are manufactured. In the past production has centered on processes, materials and costing, neglecting
the vital issue of how permanently implement new technology- implications of applying new technology to traditional
manufacturing processes. New manufacturing technologies can create life-threatening decisions for industry
competitors. These technologies can represent a huge cost for adopting firms, but may also offer the chance to
achieve competitive advantage through superior manufacturing. This work aims to evaluate how manufacturing
enterprises in Croatia implement a new technology that creates efficiencies. Croatia has not sufficiently developed
system for monitoring and encouraging new technologies, which is in all industrialized countries, the basis of market
competitiveness. The main point is to present current state, potentials and opportunities for manufacturing
technology development in Croatia.
Citation: KneeviS,SigurnjakL,DusparaM.:NewManufacturingTechnologiesinRepublicofCroatia,2ndInternationalConferenceManufacturingEngineering&Management2012,
(2012),p.9496,ISBN9788055312163
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
productionofgoods.Inthelatetwentiethcenturytheface
ofmanufacturingischanging.First,thespecialized,single
purpose equipment for mass production which had
characterized factories is being replaced by flexible
machine tools and programmable, multitask production
equipment. New machines can be quickly and cheaply
switched from one task toanother, their usepermits the
firm to produce a variety of outputs efficiently in very
smallbatches,especiallyincomparisontotheusualimage
of mass production. Over the last 200 years, the
manufacturing industry has gained significant importance
in society by introducing products which dramatically
changedtheworld.
technologies, not all of which are computerized.

Numerically controlled machine tools (NC) have been
around for decades. At first controlled by punched tape,
many of these machines are now controlled directly by a
computer.Ifacomputerisdirectlyattachedanddedicated
to the machine tool, it is called computer numerical
control(CNC).Theadvantagesofsuchequipmentare:the
consistent quality of their product, machining flexibility
andthereductioninskilledlaborrequired.CNCmachines
are more expensive than regular machine tools; they
replace such tools and thus, on a capacity basis, are not
necessarily more expensive than standard equipment.
Their risks are typically minimal, though problems may
arise for those enterprises still unfamiliar with the
technology. Robots are now an integral part of
manufacturing industry. They are sophisticated,
reprogrammable, precision, etc. Robots can offer
significantadvantagesin:quality,imageintheeyesofits
customers, competitors, and employees, safety in
hazardoussituationsandflexibility.
Newmanufacturingtechnologies
Newtechnologiesareconsideredtobethekeyfactorsin
theeconomicandsocialdevelopmentatthebeginningof
the 3rd millennium. Technology is term that includes
machinesandworkproductionprocesses,andisusually
divided on manufacturing technologies and service
technologies.Theimpactoftechnologyonorganizationis
widelyusedintheproduction,althoughitcauseschanges
intheoverallorganizationalstructureofenterprises.High
technologyautomationisanexpensivebusinessthatonly
thegiantsinindustrialeconomycanaffordtochance.The
new manufacturing technologies offer much the same
benefits to all enterprises, whether large or small. For an
implementationtosucceedusersmustlearnanddevelop
competence in using the technology, use those
competencies in the manufacturing process, and be
satisfied enough with the technology to continue using it
willingly.Themassproductionmodelisbeingreplacedby
a vision of flexible multiproduct firm that emphasize
quality and speedily response to market conditions while
utilizing technologically advanced equipment. The new
manufacturing technologies allow a drastic shortening of
thislifecycleinboththedesignandtheproductionstages.
There are a large variety of new manufacturing
Developmentofnewmanufacturingtechnologies
inCroatia
TechnologicalmodernizationofenterprisesinCroatiaand
introductionofadvancedtechnologiesornewproduction
initiate economic development. In text below are shown
main characteristics of Croatian industry and institutions
fordevelopmentoftechnologicalnetwork.
Croatianindustry
Croatian industry is intensely changed over the last ten
years has mostly been characterized by radical
manufacturing and productivity growth. Industry
generatesabout20%ofCroatianGDPandemploysaround
277 000 employees, or 25% of total employment in
Croatia. A significant proportion of the total revenue
realized by the production of food and beverages,
manufacture of petroleum products, chemicals and
chemical products, metals and building materials,
electrical and optical equipment, manufacture of paper,
printing, and shipbuilding. Industrial products represent
94
New manufacturing technologies in Republic of Croatia
S. Kneevi, L. Sigurnjak, M. Duspara
almost97%ofCroatianexports.Despitethisfact,Croatian
industry in not developed enough. Its important to
strength exports, develop manufacturing processes,
implementnewtechnologies,introducequalitystandards,
follow ecology requirements and achieve cost efficiency.
The Croatian industry as a whole has to be restructured
towards new industries based on competitiveness
achieved through knowledge, innovation, creativity,
sustainable development and advanced technology in all
areasofoperation.
Tab.1 Government budget appropriations or outlays for

researchanddevelopment
Business
Total
Year
sector
Industrial
productionand
39929
16295
2010.
technology
Industrial
productionand
17799
537
2009.
technology
Source:madebyauthorsusingwww.dzs.hr
Institutions for development of technological

network
withreferencetoinvestmentsinRepublicofCroatia.
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, transfer, application and
financing of new technologies; the development of the
systemofthenationalmeasuressupportingtechnological
development and innovation such as various financial,
fiscal, administrative and similar benefits and incentive
programs. Government has identified six major goals of
promoting business innovation and Technology
development: Promote creation and growth of
knowledgebased enterprises, creating a technology
infrastructure that will support small and SMEs based on
knowledge and newly Technologybased companies,
stimulating business demand for research and
developments, management of intellectual property,
diversityoffundingresearchanddevelopment,attracting
private sector investment and the creation of venture
capital, promoting public confidence in science and
awareness of the importance innovation. Within the
national technological network the following institutions
have been established so far: Business Innovation Centre
ofCroatiaBICROLtd.,CroatianInstituteofTechnology
HIT Ltd., Centre for Karst, Technology and Innovation
CentreOsijekLtd.,CentreforInnovativeTechnologyRijeka
Ltd., Technology Centre Split, Centre for Technology
Transfer, Research and Development Centre for
Mariculture.
Tab.2 Share of government budget appropriations or

outlays for research and development, for European
UnionandRepublicofCroatia
Industrialproductionand
technology(%)
1.
Belgium
31,5
2.
Finland
23,9
3.
Ireland
20,2
4.
Hungary
16,7
5.
Slovenia
16,7
6.
Austria
14,6
7.
Romania
14,3
8. CzechRepublic
13,6
9.
Germany
12,6
10.
Latvia
12.1
EU27
9,2
Croatia
1,7
Source:madebyauthorsusingwww.dzs.hr.
According to Table 2. Croatia is by investing in industrial
productionandtechnology,in2010amountedtoonly1,7
percent of gross domestic product (GDP), located at the
bottom of the European scale. Behind us are Poland,
SlovakiaandBulgariawhiletheallocationof,forexample,
neighboring Slovenia, reaching 16,7 percent of GDP.
Croatia lags pretty average for the European Union. As
reasonsforsmallbusinessandgovernmentinvestmentin
innovation experts usually emphasize the low awareness
of the society. Innovation is not going to hand or poor
educational structure, but no general business climate in
thecountry,wheretheproblemisnotjusttaxes,butalso
lawenforcement.Asmallinvestmentininnovationinthe
longer time will determine our future as a result will be
lower rates of economic growth. In preparation of the
industrial policy of the Republic of Croatia in the
preparation for EU membership, 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,
development and innovation for the manufacturing
industry.
Investmentsinmanufacturingtechnologies
Inahypercompetitiveenvironment,marketopportunities
quickly disappeared and competitive advantages are
quicklyreplicated.Thisleadstodecreasingprofitabilityof
anymarketsegmentandthefallofweakplayers.So,new
market opportunities and competitive advantages must
continually be searched to create or sustain market
leadership.InvestmentsinthelastfewyearsinCroatiaare
increasinglyperceivedasakindofmagicwandthatwould
beinefficienttorestructureCroatianeconomyshouldone
go and immediately create new value. The main factors
thatmotivateCroatiancompaniestodevelopandprogress
can be: innovation and business, technology and market
access,concretebenefitsfromthecollaboration,customer
innovation,theabilityofscientists,formalcompulsionand
own development. In Table 1. is shown investments in
industrial production and technology in Republic of
Croatia in 2009 and 2010. The need for access to
technology and the market is the largest in small firms,
andlowestinlarge.Successfulcompaniesarethosewitha
strongerorientationoftechnologicalinnovation,including
the existence of longterm vision of development, the
availability of new technology, importance of innovation
and new technologies, and the existence of sufficient
fundsforinvestmentinresearchanddevelopment.Table
2.showsinvestmentsinproductionandtechnologyintop
10countriesinEuropeanUnion
Advantages/disadvantagesofinvestinginnew
technology
New technology may have a lot of advantages, such as
enablinganincreaseinmassproductionofmanufactured
productsinfactories.However,itmayhavedisadvantages
thathurtbusinessandreduceprofitability.Characteristics
ofnewtechnologies:
Some new technological investments are not cheap
andforceyourbusinesstotakeondebt.
95
Country
S. Kneevi, L. Sigurnjak, M. Duspara
New manufacturing technologies in Republic of Croatia
[6]
It may be difficult to integrate the new technology

intoworkforceandmayhavetospendextrafinances
toensureitisviable.
New technology streamlines the business process,
butitalsomayresultindownsizingandoutsourcing,
makingsomejobsredundant.
Business may become susceptible to sabotage
through hacking of confidential information, which
maycomeintothepossessionofcompetitors.
[7]
[8]
CONCLUSION
EntryintotheEuropeanUnionforCroatianmanufacturing
enterprises will mean the opportunity and the challenge,
willbeexposedtogreatercompetitionandthereforeneed
toturntoinvestmentinknowledge,newtechnologiesand
innovations. Enterprises in Croatia wishing to compete
must adapt productivity and must have a high
technologicallevel.Itwillneedtoinvestininnovationand
technology because thats the way that can increase
productivity. Croatia is currently at a low level of
investmentandtheintroductionofnewtechnologiesinto
production. If you want to succeed in the global market
and be competitive to apply new technologies and new
technologicalproductionprocesses.
[9]
[10]
[11]
[12]
REFERENCES
[1]
[2]
[3]
[4]
[5]
RogerG.Schroeder:Upravljanjeproizvodnjom,Mate
d.o.o.,1999.Zagreb
Salvendy, G.,: Handbook of Industrial engineering,
Technologyandoperationmanagement,JohnWilley
andsons,3rdedition,2001,NewYork
http://www.hr/hrvatska/gospodarstvo/industrija
[Accessed:8May2012]
Drvenkar, N., FrajmanJaki, A., Croatian industry
developmentguidelines(Online)
[Accessed:28May2012].
[13]
[14]
96
Ministry of science education and sports of the

Republic
of
Croatia:
http://public.mzos.hr/Default.aspx?sec=3201
[Accessed:27August2012]
Lee, R.P, Grewal, R.: Strategic responses to new
technologiesandtheirimpactonfirmperformance,
Journal of Marketing, Vol. 68 (October 2004),
pp.157171
Bartel A.P., Lichtenberg, F.R.: Comparative
advantage of educated workers in implementing
new technology, The review of economics and
statistics,Vol.LXIX,Number1
Ander, R., Snow, D., Old technology responses to
newtechnologythreats:demandheterogeneityand
technology retreats, Industrial and corporate
change,Volume19,number5,pp.16551675
Loraas,T.M.,Diaz,M.C.:Learningnewtechnologies:
theeffectofeaseoflearning,Journalofinformation
system,Vol.25,No.2,2011,pp171.194
Wagner, H., et al., The effect of new technology
adoption on employee skill in the prosthetics
profession, International journal of production
research,Vol.46,no.22,2008,pp.64616478
Smith, L.A., Green, S.G., implementing new
manufacturing technology: the related effects of
technology characteristics and user learning
activities, Academy of management journal, Vol 45,
No.2,2002,pp.421430
Sinha, R.K., Noble C.H., The adoption of radical
manufacturing technologies and firm survival,
Strategicmanagementjournal,Vol.29,2008,pp.943
962
Naik, B., Chrakavarty, A.K., Strategic acquisition of
new manufacturing technology: a review and
research framework, International journal of
production,Vol30,No.7,2002,pp.15751601

TheProceedings
A New Design For Wireless Eddy Current Testing Probe & Its
Applications For Aircrafts
MelihCemalKushan1TolgaUnalr2EnginGode3HakanEkinci4
1
Dept.ofMechanicalEngineering,EskisehirOsmangaziUniversity,Eskisehir,Turkey,contactmail:mkushan@ogu.edu.tr
GraduateSchoolofEngineering,EskisehirOsmangaziUniversity,Eskisehir,Turkey,contactmail:tolga.unalir@eczacibasi.com.tr
AircraftMaintenance,1stAirforceCommand,Eskisehir,Turkey,contactmail:engingode81@yahoo.com
4
AircraftMaintenance,1stAirforceCommand,Eskisehir,Turkey,contactmail:hakanhanekinci@gmail.com
2
3
ARTICLEINFO:
Received:14September2012/Revised:2November2012/Accepted:13November2012
Abstract:
Aircraftmaintenance
Currenttestprobe
Wirelesseddy
TheUseofEddyCurrenttestingmethodisverycommoninaircraftmaintenancefield.Theaimofthisstudy
istodesignwirelessEddyCurrenttestprobeinaircraftmaintenanceapplications.Newprobedesignandits
applicationswerestudiedinthispaper.
Citation: Kushan MC. et al.: A New Design For Wireless Eddy Current Testing Probe & Its Applications For Aircrafts , 2nd International Conference Manufacturing Engineering &
INTRODUCTION
EddyCurrentTestingmethodhasawideusageinthefield
of Industry. Especially, aircraft maintenance field has so
manyapplicableareasforthismethod.Inaddition,awide
variety of inspections and measurements may be
performed with the eddy current methods that are
beyond the scope of other techniques. Measurements of
nonconductivecoatingthicknessandconductivitycanbe
done.Conductivityisrelatedtothecompositionandheat
treatment of the test material. Therefore, 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. [1] By
designing Wireless Eddy Current Probe for all aircraft
maintenance inspections, effective and flexible operation
conditions can be reached. The first prototype wireless
eddy current (EC) probe for onwing inspection was
demonstrated in a F100 PW220 engine without external
cabling at the Air National Guard overhaul facility in Des
MoinesIowa.[2]
A.BasicPrinciplesofNonDestructiveTesting(NDT)
Nondestructive testing is the use of physical methods
which will test materials, components and assemblies for
flaws in their structure without damaging their future
usefulness. NDT is concerned with revealing flaws in the
structureofaproduct.
B.EddyCurrentTesting(ET)
Thismethodiswidelyusedtodetectsurfaceflaws,tosort
materials,tomeasurethinwallsfromonesurfaceonly,to
measure thin coatings and in some applications to
measure casedepth. This method is applicable to
electricallyconductivematerialsonly.Inthemethodeddy
currents are produced in the product by bringing it close
to an alternating current carrying coil. The alternating
magnetic field of the coil is modified by the magnetic
fields of the eddy currents. This modification, which
depends on the condition of the part near to the coil, is
then shown as a meter reading or cathode ray tube
presentation.Fig.1showsbasicETsystem.
Fig.1BasicEddyCurrentTestingMethod
1) Types of Probe: The eddy current probes can have a
varietyofforms.Thechoiceofthetypedependsuponthe
test situation. Following are the three major types of
probemainlyusedineddycurrenttesting:
a)Internal(bobbintype)probe.
b)Encirclingprobe.
c)Surfaceprobe.
Internalprobes
Internal probes consist of circular coils used to test the
interior of tubes or circular holes. Fig. 2 illustrates a type
of coil which can be inserted into a tube to inspect
discontinuitiesontheinnercircumferenceofthetube.As
with the encircling coil, the internal coil induces currents
thatencircletheentirecircumferenceofthetubesothat
theentiresectionsurroundingthecoilisinspected.Asthe
currents induced in the material are strongest near the
coil,theinternalcoilismoresensitivetodefectslyingon
orneartheinnersurfaceofthetube.
97
M. Cemal Kushan et al.
A New Design For Wireless Eddy Current Testing Probe & Its Applications For Aircrafts
1 WIRELESSEDDYCURRENTPROBE
1.1DesigningofWirelessEddyCurrentProbe
The first prototype wireless eddy current (EC) probe for
onwing inspection was demonstrated in a F100 PW220
enginewithoutexternalcablingattheAirNationalGuard
overhaul facility in Des Moines Iowa. The results were
compared to a wired EC tester. Fig. 5 shows a block
diagramoftheprototypewirelessprobesystem.
Fig.2InternalProbe
Encirclingprobes
Encirclingprobesaresimilarinstructuretointernalprobes
except for the fact that the test material is passed inside
the coils. They are primarily used to inspect the outside
surface of round materials such as tubes and rods. Fig. 3
shows an encircling coil. The magnetic field induces eddy
currents in thebar that encircle the entire circumference
ofthetubeorrodsothattheentiresectionunderthecoil
isinspectedatanyoneinstance.Thewidthofthecoilisa
function of the application. Wide coils cover large areas,
so they respond mostly to bulk effects, e.g. conductivity,
whereas narrow coils sense small areas and so are more
responsive to small changes such as those produced by
discontinuities. The magnetic field of the coil extends
slightlybeyondtheendsofthecoil.
Fig.5 Block Diagram of The Prototype Wireless EC Probe

System
ResultswerecomparabletowiredandstateoftheartEC
technology used to inspect engines. The study showed
that wired eddy current probes could be converted to
wirelessprobes[2].
Generally, in maintenance applications wireless systems
arerequiredtocontrolsurfaceseasily.Cablesystemshave
so many difficulties for inspection in that it limits the
control area due to its equipments. Flexibility in
maintenance working areas is considerable when
encounteredsmallandcomplexcontrolareas.
Our aim is to design a new wireless Eddy Current probe
instead of wired systems. Furthermore, we intend to
measure defect sizes as absolute values rather than
intervalvaluesasinconventionalEddyCurrentinspection.
By using more visual LCD monitors we will be able to
transmit a data to another monitor and reach various
inspectiondataregardingprecedinginspections.Flexible
probeholderisotherpartoftheourdesign.Bymeansof
this apparatus complex surfaces will be able to reached
easily.
Fig.3EncirclingProbe
Surfaceprobes
Surface probes are one of the most widely used eddy
current probes for inspecting surfaces, flat or contoured
for defects or material properties. Defects can either be
surface or subsurface. These are also called probe coils.
Fig. 4 shows a typical surface probe. The surface probe
may be hand held or mounted in automated scanning
equipment. The coil mounted in the end of the probe is
providedwithaprotectivecoatingofepoxytoserveasa
wear surface. The magnetic field produced by a coil is
approximately of the size of the coil. Other variations of
surfaceprobedesignsarepancakeprobe,flatprobe,horse
shoe or gap probe, spring loaded probe spinning probe
andpencilprobe[3].
1.2ApplicationsofWirelessEddyCurrentProbe
It is thought that Eddy Current Testing Device will work
more efficiently and functionally with wireless probe in
aircraft maintenance activities. The operator will reach
complexandnarrowworkplacesswimmingly.Fig.6shows
thiskindofaplace[4].
Fig.6AgiriftAircraftnspectionArea.
Indifficultworkspacesindifferentapplicationssuchason
aircraftbodyoperations,narrowareas,unfixedonground
operations, the cable arise as a hindering occasion. The
cable makes difficult working conditions and leads to
signaldeterioration.Fig.7andfig.8showsomeexamples
ofsuchdifficultoperations.
Fig.4SurfaceProbe
98
A New Design For Wireless Eddy Current Testing Probe & Its Applications For Aircrafts
M. Cemal Kushan et al.
REFERENCES
[1] J.G. Martin, J.G. Gil, E.V. Sanchez, NonDestructive
Techniques Based On Eddy Current Testing Sensors
2011, 11, Feb. 2011, pp. 25252565,
doi:10.3390/s110302525
[2] M. Reid, B. Graubard, R. J. Weber, J. A. Dickerson,
K.Smith, D. Raulerson, L.Brasche, G. Y. Baaklini,
Wireless Eddy Current Probe for Engine Health
Montoring Quantitative Nondestructive Evaluation,
AIPConferenceProceedings,Volume700,Feb.2004,
pp.414420,doi:10.1063/1.1711652
[3] Internaitonal Atomic Energy Agency, Training
CourseSeries48,EddyCurrentTestingatLevel2:
Manual for the Syllabi Contained in IAEATECDOC
628/Rev. 2, Training Guidelines for NonDestructive
TestingTechniques,Vieanna2011,pp.1121.
[4] M.C. Kushan, T.Unalr, E.Gode, H.Ekinci, Wireless
Eddy Current Probe Design and Applications In
Aircraft Maintenance Mechanical, Electrical and
Computer Engineering Conference, Singapore, Aug.
2012,pp.2224,ISBN:9789382208051.
Fig.7EddyCurrentInspectionofanAircraftPart
Fig.8EddyCurrentInspectionofanAircraftPart
Wirelessprobesystemwilleliminateallthesedestructive
effects.
ACKNOWLEDGMENT
The authors wish to acknowledge 1st Main Jet Base NDT

aircraftmaintenancestaffsfortheirsupports.
99

TheProceedings
Verification of Sequential Patterns in Production Using Information

Entropy
IvanLazr1
1
FacultyofManufacturingTechnologies,TechnicalUniversityofKoice,Bayerova1,08001Preov,Slovakia,ivan.lazar@tuke.sk
ARTICLEINFO:
Abstract:
Networkcomplexity
Shannonentropy
Scheduling
Simulationmodel
Throughputofproductionsystem
One of the biggest problems in production system is comprehensive system to verify condition of all equipment. In
this paper are joined three different issues to one verification system. This system includes: scheduling part,
simulation part and part of that is taken from information theory and is called Shannon entropy. This entropy is used
in information science to determine complexity of information and to finding its benefit.
Citation:LazrI. VerificationofSequentialPatternsinProductionUsingInformationEntropy,2ndInternationalConferenceManufacturingEngineering&Management2012,(2012),p.
100106,ISBN 9788055312163
INTRODUCTION
This complexity or network complexity of production
systemcanbecloserspecifiedusingShannonentropy.The
entropic measurement was first derived by Shannon in
1948[3].Thistheoryiswellknownasinformationtheory
and provides a measure of the amount of information
associated with the occurrence of given states. The
entropyofasystemcanbewrittenas:
Withtheadventofjustintimemanufacturingphilosophy
which maintains a limited inprocess inventory, the flow
shop scheduling problem with minimum makespan and
optimization approaches to minimize manufacturing cost
started to be intensively studied). Flowshop scheduling
problems present an important class of sequencing
problems in the field of production planning. 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.e. flowtime [1].The permutation flow
shop scheduling problem (PFSP) is often designed by the
symbols n|m|P|Cmax, where n jobs have to be processed
onmmachinesinthesameorder.Theprocessingofeach
job on each machine is an operation which requires the
exclusive use of the machine for an uninterrupted
durationcalledtheprocessingtime.Pindicatesthatonly
permutationschedulesareconsidered,wheretheorderin
whicheachmachineprocessesthejobsisidenticalforall
machines.Henceascheduleisuniquelyrepresentedbya
permutation of jobs. 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. In a
statistical review of flowshop scheduling research,
Reismanetal.concludedthatthereislackofrelevanceto
practice for the overall majority of research in this field
[2]. According to previous findings the order of parts on
the entering the system affects to some extent a
complexityofthesystem.
(1)
log
(2)
where:
pij:Probabilityofresourceibeinginscheduledstatej
S:Numberofscheduledstates
M:Numberofstations
DEFINITIONOFENTROPY
We therefore define uncertainty entropy H (P) = {P
experimentA1,A2,...,An},wherealltheeventsAihavethe
sameprobability1/ninthiscaseisH(P)=log2(1/n).
But what if events do not have the same probability
experiment?Supposethat=A1 A2,A1A2= ,P(A1)
= 0,1, P (A2) = 0,9. If the result of the experiment A1, we
get the information I (A1) =log2 (0,1) = 3,32 bits, but
whereitbecomesA2,wegetonlyinformationI(A2)=log2
(0,9) = 0,15 bits. The resulting information thus depends
on the outcome of the experiment. If it A1, we're doing
very well, but, it happens only one tenth of the cases. In
90%ofcases,however,comesA2andthemajorityofcases
we're doing wrong to get information [6]. Suppose now
that the experiment was carried out a large number of
times e.g. 100 times. In about ten cases, get the
100
Where H is the entropy of a system S consisting of N

differentstates,fromi=1,...,N.Piistheprobabilityofthe
system being at state i. By borrowing the notion of
entropyfrominformationtheory,wecandirectlyapplyit
to manufacturing systems. We use entropy asdefined by
Shannon to measure variety and uncertainty within
manufacturing systems [3]. Two classes of complexity
havebeenidentified:structuralandoperational[4].Inthis
paper, we will focus on structural complexity. The
structural complexity of a multistation system can be
definedas[5]:
Complexity: The complexity is one of the features that

characterizesystems.Complexityisbasedon:
Fig.1Dependenceofsystemcomplexity
log
Verification of Sequential Patterns in Production Using Information Entropy
I. Lazr
part of it. In such cases, can be used in structural

complexity theory, and this is the first problem [5]. The
second problem is the lack of process analysis network.
From the literature (Deshmukh, 1993, Calinescu, 1997,
2000) is the main objective to evaluate the impact of
changes in the complexity of the product, number of
stations,integrationandproductrange[4,8].Influenceof
different networks and linkages is analyzed and it is not
verydifficulttodeterminetheeffectivedistributionandto
makechangestoimproveoverallperformance.Thispaper
seeks to address these problems. Network complexity is
defined as the structural complexity of the production
network (system). It is a quantitative measure that
captures the impact of network forms, affect the
availabilityandrecoverystations/machines.
information bits 3,32, approximately 90 cases, get the

information bits 0,15, the overall information obtained
can be quantified as 10 3,32 +90 0,15 = 33,2 +13,5 =
46,7 bits. The average information per experiment is
46,7/100=0,467bits.Oneoption,asinthegeneralcaseis
anattempttointroduceentropytodefineitasthemean
information[6].
Shannon'sdefinitionofentropy.
Let(,A,P)isaprobabilityspaceonwhichinformationis
given by I (A) =log 2 P (A). Let P = {A1, A2, ..., An} is
experiment. Entropy H (P) of experiment P is mean a
discrete random variable X which takes on a subset Ai
valueI(Ai)t.j.
. log
,(3)
PRIORITYRULES
Priorityrulesprovideguidelinesforthesequenceinwhich
jobs should be worked. The rules generally involve the
assumptionthatjobsetupcostandtimeisindependentof
processingtimes.Inusingthisrules,jobprocessingtimes
and due dates are important pieces of information. Job
times usually include setup and processing times. Due
dates may be the result of delivery times promised to
customers, MRP processing, or managerial decisions. The
rules are especially applicable for processsfocussed
facilitiessuchasclinics,printshopandmanufacturingjob
shops. Priority Rules try to minimize completion time,
number of jobs in the system, and job lateness, while
maximizingfacilityutilization.
A consistent reader should now be able to ask what

happenswheninexperimentP={A1,A2,...,An},thesetAi
occurs with zero probability. Then, the expression P (ai).
log2 P (Ai) is not defined. Because lim
log
,is
naturaltosupplementfunction(x)asfollows
x

log
0
0
,
0
(4)
Then by Shannon's formula for entropy should be in the

form
(5)
However, such entry obscures some form of nonzero

summandsformula,andsowedoagreeasfollows:
ShortestProcessingTime(SPT)shownonFig.4
Theshortestjobarehandledfirstandcompleted.
LongestProcessingTime(LPT)shownonFig.5
Thelongestjobarehandledfirstandcompleted.
EarliestDueDate(EDD)shownonFig.3
The job with the earliest due date is selected first by
usingEDD.
Thestepsareusingthisruleare:
Firstly,theuserwillinput:
thenumberofjobs,
thejobnames,
theprocessingtime,
the due date of each job or use the

datavaluesgivenatthestartingpoint.
The second step is sorting out the earliest due

dateamongthejobs.
Thirdly, calculate the flow time of each job by

using the processing time. The flow time is the
accumulations of processing time each job by
eachjob.
Agreement:
From now we will assume that the term 0.log2 (0) is
defined, and the 0.log2 (0) =0. This well reflects the fact
that if some experiment P (i.e. a measurable
decomposition of the set ) we add the empty set (i.e.
impossible outcome), we get a new trial P ', and the
uncertaintywillbethesameasinexperimentP[7].From
equation(2)canbeseenthatthereductionofcomplexity
can be achieved by simplification. Less processes, fewer
statesandfewervariationsinconditionsthatmaytaketo
reducecomplexity.Onreducingthecomplexityshouldbe
the priority objectives of the reorganized system and
reducing costs. However, this equation can only work
provided that the conditions of one station are not
dependentonchangesinconditionsatthesecondstation.
This means that if there is any condition (expected and
unexpected)ononechannelwillnotaffecttheoperation
of other stations. For example, consider a system
consisting of three stations that are connected in series.
The product enters the first Phase A station, and then
continuestostationBinthesecondstageetc.
Thedelaysiscalculatedfromtheflowtimeandduedate.
Tab.1ProcessingtimesJ1J4onallmachines
Machine/Job
M1
M2
M3
M4
M5
M6
M7
M8
M9
M10
Fig.2Examplelinematerialflowsystem
If station A failure occurs, the station B and C must
unceasinglycontinuetooperateiftheyhaveanunlimited
supplyofinputlinesortank.Inthiscase,wecansaythat
the stations are independent of each other and we can
usethefourthequationInpractice,theaboveassumption
of"independence"canbedifficulttoachievebecausethe
size or storage tank is still limited. This means that the
station B and C will stop if the buffer is emptied. In the
caseofautomatedproductionforsuchcasesisnotready,
notemporarystorageontheproductionline.Thesecond
caseisthatitstopsthewholesystembreaksdownwhena
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
I. Lazr
Fig.3EDDschedulewithsequence1234
Fig.5LPTschedulewithsequence3412
Processingtimeofalljobsis:
SPTrule104min
LPTrule117min
EDDrule105min
Processing time in this case does not include
transportationtime,repairtimeandfailures.
Fig.4SPTschedulewithsequence2143
Fig.6Schemeofformationofsimulationmodel
When creating a simulation model is required to realize
that the simulation respectively simulation model is an
accurate model of reality, but it is not on real time. To
createasimulationmodel,weneedtoidentifyallaspects
thataffecttherealsystem,becausetheinterferencemust
be applied in the simulation. Fig. 6 shows the process of
simulationmodelwithalltheinterferencedeterminedby
themanufacturingsystemtooperate.
First we must identify all input data. The input data are
key information affecting the model and simulation
programsareusuallyawardedevenbeforesimulating.The
maininputdataaremainly:
minumberofmachines,
njnumberofoperations,
gijleadtime,
pijprocessingtime,
Tijtotalprocessingtimeofthejthoperation,
riearliestpossiblestartprocessingjobJi,
didesiredtimeforthejobJi,
ai=dirimaximumpermittedlengthofstayjob
Jiinthesystem,
ficostfunctionfi,
Cicompletiontimejthoperation
Limachinedowntime
Another part of this diagram is information about the

deploymentmachine.Ifwewanttocreatethemostexact
modelweneedtoplanthedeploymentofmachinesinthe
simulation model, because any difference in distance
between model and real production system can brings
erroneousinformationtoothercalculationsdistancesand
transporttimes.
The third part of the diagram is prioritizing access to
production parts. Prioritizing access to system
components is very important because it is essential to
identifywhatcomponentparametersforeachfollow.Itis
essential that it is necessary to machine the parts
completely change sort or just modify a dimension
possibly tool. This chart graphically expresses the main
aspectsonwhichweconsiderinthesimulation.Ascanbe
seeninFig.7,whichpresentsasimulationmodelcreated
using Witness from the Lanner Group. At the outset of
developing the model we had to specify the number of
simulation values. First we must define the time (length)
of simulation. Given our program in this area provides
manyoptions.Simulationcanbecarriedoutduringseveral
periods,suchas:
unlimitedlengthofsimulation,
simulationforoneday,
simulationduringselectedhours,
simulationduringoneshift,etc.
102
I. Lazr
graphiccharactersandabsolutelymeetsiftheparameters
are the same distances and times. In such cases it is not
necessary to insert socalled layout to the model.
Simulation also allows us to monitor the capacity of
warehouses, buffers and current status of parts on
machines. The outputs of these simulations are of great
benefit.
Another important information and choice is layout of

machines. Machines can be deployed freely in the
simulationfieldorinthelayoutthatyoudownloadedfrom
a predetermined menu or from a file *. dwg which is
create in AutoCAD. The deployment of machines should
respond to the real state of the company, but often are
similar only in numerical terms. In some cases, it is
immaterial whether the model corresponds to reality in
Fig.7Simulationlayoutwithdescription
Thesimulationincludes:Parts:Part1Part4,machines:M1
M10, Conveyors: Conveyor1Conveyor8, Buffers: SCH1
SCH6, Outlet stores: OS1OS4, Employees: Operator1
Operator8.
The simulation model can express mathematically even
prior simulate. This graphical representation is called
mathematical model of the real production system. In
thus mathematical models we are considering each
machine as a separate element, which acts on its
surroundings and environment acts on it. Each machine
has its internal interactions and conditions that we
describe in any simulations. These external and internal
functionsofmachinesaregenerallydescribedinFig.8.
The results of simulations are probabilistic and can be
used to estimate statistical parameters of search. Thus,
simulation is an approximate method. It is possible to
achieve arbitrary precision values, which increases
approximately with the square of the length of the
simulation. Cost simulations are rising approximately
linearlywiththelengthofthesimulation[9].
mathematical modeling is the opposite of physical

modeling,butratheritcomplementsthemethodsof
mathematicalanalysis.
Fig.8Descriptionoftheseparateelementsofthe
mathematicalmodel.
ADEQUACY OF THE MATHEMATICAL MODEL OF A

REALOBJECTINDICATORS
model has sufficient accuracy to describe both

quantitativeandqualitativepropertiesoftheobject,
mathematical description of the measure is
comparing by the measured values and values that
has a mathematical model under the same
conditions,
mathematical modeling can at relatively low cost
test several variations of their properties and to
detectpossibledefects,
Fig.9Mathematicalmodel(schema)ofrealproduction
system.
Thevaluesofprobabilitiesofstatesondifferentmachines.
Onthemachinescancameaboutsevenstates,wherefor
each machine can occur at the same time only one of
theseconditions:
103
I. Lazr
1.
2.
3.
4.
5.
6.
7.
Idle
Busy
Blocked
Cyclewaitlabor
Setup
Setupwaitlabor
Brokendown
simulation tool give us their automatically extract to the

simulationfield.
These conditions are appropriate in this case ten

machines. This means that each machine may be in the
only one of theabove conditions simultaneously. Each of
thesestatespertainstoacertainamountofprobability.It
is likely that at a particular time the machine is in the
state. All the probabilities of a machine together give a
value1.Darkboxmarkedstates,whichoccurredonthe
specifiedmachines.Thesestatesofmachinescanbecalled
naturalorbasic.Onereasonisthatmostofthemarepre
programmed into the simulation tool. The second reason
is that at least one of these conditions occurs during the
simulationforeachmachine.Fig.10isdescribedasastate
machineandmarkedwithspecificcolors.
Fig.11OptionalstatesofmachineinWitnesssimulation
tool
The abovementioned simulation model contains 10
machines. Each of these machines has undergone a
number of components. On some machines there was a
state of inequality. Status inequality occurs when the
number of input components is equal to the number of
components at the output. This may be the case if the
machine that created malformation (scrapped part) or
other unexpected failure occurs. Greatest number of
componentsinthiscasepassedthroughthemachineM6.
Then Working rate (Wi) M6 machine reaches Wi = 1
Workingrateofothermachineryisthen:
Fig.10BasicstatesofmachineinWitnesssimulationtool
(6)
where x=6 in our case, andNpSi is anumber of

components,thatcrossedoverithmachine.
Anothertypesofstateswemanuallyprogrammedintothe
simulationmodel.Thesetypesofstatesmaybedescribed
as "optional states." Optional states are programmed to
Tab.2Statesofmachinesincaseofsequence1234
Name
Idle
Busy
Blocked
CycleWaitLabor
Setup
SetupWaitLabor
BrokenDown
State
S1
S2
S3
S4
S5
S6
S7
M1
0,6
0,14
0,04
0
0,193
0
0,015
M2
0,55
0,20
0,006
0
0,228
0
0,007
M3
0,487
0,19
0,044
0,045
0,146
0,058
0,009
M4
0,610
0,192
0,046
0,001
0,142
0
0,006
M5
0,787
0,203
0,007
0
0,004
0
0
M6
0,225
0,54
0,228
0
0,001
0
0
M7
0,172
0,067
0,094
0
0,67
0
0
M8
0,632
0,099
0,006
0
0,261
0
0
M9
0,61
0,272
0,011
0
0,103
0
0
M10
0,93
0,067
0,001
0
0,001
0
0
Workingrate
Wi
0,8
0,91
0,85
0,85
0,88
0,71
0,44
0,34
0,29
CALCULATIONOFCPL(
Tab.3Calculationofcomplexity
S1
S2
S3
S4
S5
S6
S7
M1
0,4421
0,4092
0,2088
0
0,4588
0
0,0908
M2
0,4743
0,4691
0,0448
0
0,4867
0
0,0506
M3
0,5055
0,4586
0,2004
0,2013
0,4059
0,2382
0,0643
M4
0,4348
0,4572
0,2043
0,0099
0,4008
0
0,0489
M5
0,2710
0,4669
0,0501
0
0,0376
0
0
CALCULATIONOFTH(
104
M6
0,4842
0,4765
0,4867
0
0,0099
0
0
M7
0,4371
0,2620
0,3206
0
0,3871
0
0
M8
0,4178
0,3310
0,0442
0
0,5062
0
0
M9
0,4328
0,5109
0,0725
0
0,3394
0
0
M10
0,0937
0,2620
0,0099
0
0,0099
0
0
I. Lazr
Tab.4Calculationofthroughput
M1
M2
M3
M4
M5
M6
M7
M8
M9
M10
S1
0,48
0,44
0,3896
0,4881
0,63024
0,18
0,13784
0,50616
0,49032
0,74616
S2
0,1192
0,1644
0,1548
0,1536
0,1624
0,43704
0,05384
0,07952
0,2176
0,05384
S3
0,038
0,0048
0,0357
0,0368
0,0056
0,18296
0,0752
0,0048
0,00896
0,0008
S4
0,036
0,0008
S5
0,1551
0,1829
0,1172
0,1141
0,00392
0,0008
0,536
0,20952
0,08312
0,0008
S6
0,0464
S7
0,012
0,0056
0,0076
0,0054
The resulting complexity and throughput values for the

selectedsystemcomponentsandtheorderof1234:
CPL=13,49
Th=7,882
Name
Idle
Busy
Blocked
CycleWaitLabor
Setup
SetupWaitLabor
BrokenDown
State
M1
M2
S1
0,589 0,545
S2
0,1449 0,2058
S3
0,051 0,0068
S4
0
0
S5
0,2026 0,2343
S6
0
0
S7
0,0146 0,0073
M3
0,5246
0,1803
0,0318
0,015
0,1423
0,0966
0,0095
M4
0,6376
0,1723
0,05
0,0002
0,1328
0
0,0066
M5
0,7923
0,1876
0,0157
0
0,0044
0
0
M6
0,2325
0,5164
0,2511
0
0
0
0
M7
0,19
0,065
0,0869
0
0,6624
0
0
M8
M9
0,6617 0,625
0,0956 0,2682
0,0153 0,0152
0
0
0,2274 0,0916
0
0
0
0
M10
0,9336
0,0664
0
0
0
0
0
Tab.6Calculationofcomplexityincase2
S1
S2
S3
S4
S5
S6
S7
M1
0,449
0,403
0,218
0
0,466
0
0,089
M2
0,477
0,469
0,048
0
0,490
0
0,051
M3
0,488
0,445
0,158
0,090
0,4
0,325
0,063
M4
0,413
0,437
0,216
0,002
0,386
0
0,047
M5
0,266
0,452
0,094
0
0,034
0
0
M6
0,489
0,492
0,5
0
0
0
0
M7
0,451
0,256
0,306
0
0,393
0
0
M8
0,394
0,323
0,092
0
0,485
0
0
M9
0,423
0,509
0,091
0
0,315
0
0
M10
0,092
0,259
0
0
0
0
0
M4
0,522
0,141
0,041
0,001
0,108
0
0,005
M5
0,649
0,153
0,012
0
0,003
0
0
M6
0,190
0,423
0,205
0
0
0
0
M7
0,152
0,053
0,071
0
0,543
0
0
M8
0,542
0,078
0,012
0
0,186
0
0
M9
0,512
0,219
0,012
0
0,075
0
0
M10
0,765
0,054
0
0
0
0
0
Tab.7Calculationofthroughputincase2
S1
S2
S3
S4
S5
S6
S7
M1
0,482
0,118
0,041
0
0,162
0
0,011
M2
0,446
0,168
0,005
0
0,192
0
0,005
M3
0,430
0,147
0,026
0,012
0,116
0,079
0,007

CPL=12,7
Th=8,07
Name
State
Idle
S1
Busy
S2
Blocked
S3
CycleWaitLabor
S4
Setup
S5
SetupWaitLabor S6
BrokenDown
S7
M1
0,566
0,156
0,053
0
0,207
0
0,016
M2
0,51
0,222
0,005
0
0,245
0
0,007
M3
0,489
0,198
0,038
0,001
0,15
0,095
0,01
M4
0,611
0,187
0,055
0,001
0,138
0
0,007
105
M5
0,776
0,201
0,017
0
0,005
0
0
M6
0,195
0,562
0,241
0
0,001
0
0
M7
0,134
0,078
0,099
0
0,687
0
0
M8
0,613
0,11
0,001
0
0,263
0
0
M9
0,589
0,229
0,001
0
0,104
0
0
M10
0,924
0,075
0,001
0
0,001
0
0
I. Lazr
Tab.9Calculationofcomplexityincase3
S1
S2
S3
S4
S5
S6
S7
M1
0,464
0,418
0,224
0
0,470
0
0,095
M2
0,495
0,482
0,043
0
0,497
0
0,052
M3
0,504
0,462
0,179
0,009
0,410
0,322
0,066
M4
0,434
0,452
0,230
0,009
0,394
0
0,05
M5
0,283
0,465
0,099
0
0,037
0
0
M6
0,459
0,467
0,494
0
0,009
0
0
M7
0,388
0,287
0,330
0
0,372
0
0
M8
0,432
0,350
0,009
0
0,506
0
0
M9
0,449
0,486
0,009
0
0,339
0
0
M10
0,105
0,280
0,009
0
0,009
0
0
M4
0,51
0,157
0,046
0,001
0,115
0
0,005
M5
0,651
0,168
0,014
0
0,004
0
0
M6
0,16
0,472
0,202
0
0,000
0
0
M7
0,112
0,065
0,083
0
0,577
0
0
M8
0,514
0,092
0,001
0
0,220
0
0
M9
0,494
0,192
0,001
0
0,087
0
0
M10
0,776
0,063
0,001
0
0,001
0
0
Tab.10Calculationofthroughputincase3
S1
S2
S3
S4
S5
S6
S7
M1
0,475
0,131
0,044
0
0,173
0
0,013
M2
0,428
0,186
0,004
0
0,206
0
0,006
M3
0,41
0,166
0,031
0,001
0,126
0,0798
0,008
REFERENCES

[1] Sule, D.R. (1982), Sequencing n Jobs on Two

Machineswithsetup,processingandRemovalTimes
Separated,NavalRes.Log.Quart.Vol.29,No.3,517
519
[2] Reisman,A.,Kumar,A.,Motwani,J.,(1997).Flowshop
scheduling/sequencing research: A statistical review
of the literature, 19521994. IEEE Transactions on
EngineeringManagement,44,316329.
[3] SHANNON, C.E. (1948), AMathematical Theory of
Communication,BellSyst.Tech.J.,27,379423,623
659
[4] FRIZELLE, G., WOODCOCK E., (1995), Measuring
complexity as an aid to developing operational
strategy, Intl Journal of Operations & Production
Management,Vol15,No.5,
[5] HANKERSON, D., HARRIS, G.,A., JOHNSON, O.,D.,
(1998), Jr.: Introduction to Information Theory nad
DataCompression,CRCPressLLC,ISBN084933985
5
[6] SARNOVSK, J., LIGU, J., BENKO, P. , (2002),
Kybernetikaamanament.Koice:Elfa.
[7] DESHMUKH, A. V., (1993), Complexity and chaos in
manufacturing systems, Ph.D. Thesis, Purde
University.
[8] CALINESCU, A., EFSTATHIOU, J., SIVADASAN, S.,
SCHIRN, J. AND HUATUCO, L. H., (2000), Complexity
inManufacturing:Aninformationtheoreticapproach,
Proceedings of International Conference on
ComplexityandComplexSystemsinIndustry.
[9] HATALA, M., DUPLAK, J., ORLOVSKY, I., (2011),
Comprehensive identification of cutting ceramic
durabilityinmachiningprocessofC60,1elektronick
optick disk (CDROM).In: Progresivn metody ve
vrobnch technologich : sbornk anotac pspvk
sympozia:mezinrodnvdecksympozium:Pern,
3.11.5.11.2011. Ostrava : VBTU, 2011 P. 15.
ISBN9788024825021
CPL=13,46
Th=8,181
CONCLUSION
System complexity is in today's technologically advanced
andmoderntimesoftendiscussingtopic.Eachproduction
system or a nonmanufacturing system can be
characterized by the concrete value of complexity. This
articleproposesonewayhowcanbegiventhecomplexity
monitoredandpositivelyinfluenced.Evenasmallchange
of complexity, can bring about great changes in practice
andinsomecasessavealotofmoneytoinvest,orrepair.
In our case, we simulated the production process only 4
components, where we watched the status changes of
individualmachines,andthentheprobabilitythatagiven
machinestudiedphenomenonoccurs.Inthefirstcase,we
chosea1234sequenceusinginformationtheoryweget
thecomplexityofthevalue13,49.Whenwastheselected
order 2143 we get the complexity of the value 12,07
andinthethirdcase3412wegetthecomplexityofthe
value of 13,46. This means that only with the four
components achieve reducing the complexity of 1.42. On
theotherhandwehavethischangecamethesequenceof
inputs to reduce system throughput by 0.299. There are
significant changes in values, but in practice can bring
huge savings, not to mention the production process,
whichproduced1,000representativescomponentbase.
106

TheProceedings
Quality Assurance of a Large Welded Penstock Manufacturing by

Means of Full-scale Model Testing
AlgoulM.Mahdi1AleksandarS.Sedmak1BlagojPetrovski2UrosS.Tati2SimonA.Sedmak2
AndrijanaA.Djurdjevic2
1
FacultyofMechanicalEngineering,UniversityofBelgrade,KraljiceMarije16,11000Belgrade,Serbia,mail:asedmak@mas.bg.ac.rs
InnovationCenteroftheFacultyofMechanicalEngineering,KraljiceMarije16,11000Belgrade,Serbia
ARTICLEINFO:
Abstract:
Fullscaletesting
Pressurevessel
Welding
Qualityassurance
Thepaperdealswiththefullscalemodeltestingasacrucialstepinthequalityassuranceofalargewelded
penstockmanufacturing.ThishasbeendoneinaccordancewithISO9000series,whereweldingisdefined
asaspecialprocesssinceweldscannotbefullyverifiedbysubsequentinspection.Thefullscalemodelhas
been tested by a sequance of increasing pressure, ending well above local yield stress levels. In this way
overallbehaviourofthelargeweldedpenstockhasbeenverified,includingresistanceofweldments,asthe
weakestpoints,tocracklikedefects.
Citation:MahdiA.M.etal.:QualityAssuranceofaLargeWeldedPenstockManufacturingbyMeansofFullscaleModelTesting,2ndInternationalConferenceManufacturingEngineering
&Management2012,(2012),p.107108,ISBN9788055312163
INTRODUCTION
Within the ISO 9000 series of standards for quality
systems, 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. Therefore,
processingdefiniciesmaybecomeapparentonlyafterthe
product is in use. Accordingly, continuous monitoring
and/or compliance with documented procedures is
required to ensure that the specified requirements are
met. ISO3834/EN729 series of standards have been
prepared to describe welding quality requirements
suitableforapplicationbymanufacturersusingweldingas
ameansoffabrication.Moreorlessextensivedestructive
and nondestructive testing should be performed,
depending on the requirements level, determined
according to the responsibility of welded joints and the
overallrisklevel.Anyhow,insomecases,onlyafullscale
testing provides complete insight in welded joints and
complete construction behaviour, and thus, presents the
crucialstepinqualityassuranceprocedure.Thenecessity
toperformtestingoffullscalemodelwasrecognizedalso
in the case of penstock of reversible hydroelectrical
power plant Bajina Bata, which was produced of high
strengthlowalloysteel(nominalyieldstrength700MPa)
about 40 years ago, [1]. Due to limited experience in
welding of steel of this strength class, certification of
welders, welding procedure specification and its
qualification were strictly required, similarly to nowadays
approach accepted in standards EN287 and EN288. In
addition, a kind of fitness for purpose was required, in
order to understand better crack significance. Following
facts additionally contributed to make a decision to
producetwofullscaleprototypesofthispenstockinorder
togatherthedataaboutitsintegrity:
1. The selection of mild structural steel of yield strength
350 MPa for penstock of requested capacity required
expensivesolutionwithtwopenstocksandtwotunnels.
2.Foronlyonepenstocktheapplicationofstructuralsteel
of yield strength level 700 MPa was inevitable. This
requirementcanbesatisfiedbyHT80,weldable,quenched
and tempered, low alloy high strength steel (HSLA), with

ultimatetensilestrengthabove800MPa.
3.SelectionofHSLAsteelopenedtwonewproblems.The
plate thickness in the penstock most stressed part is 47
mm, and this was regarded as the upper limit in plate
fabrication for this steel class. The maximum thickness in
previouslyconstructedpenstockswiththissteelisonly32
mm.Thesecondproblemwasadoptedlowsafetymargin
of only 1.7 regarding steel yield strength according to
German specification for the HSLA steel. According to
other specifications, a higher safety margin is required,
e.g. Japanese experience with this steel grade
recommendedaminimumsafetymargin2.07.
4. Penstock welding was to be partly performed in the
field. i.e. tunnel conditions and strict requirements could
be satisfied only with educated, skilled and approved
personnel. Practical training had to be done prior
fabricationofpenstock.Theselectedmanufacturerswere
for the first time in situation to weld a penstock of a
quenched and tempered HSLA steel of 700 MPa yield
strengthand47mmthick.
Theoverallbehaviorofaweldedpenstockunderloadwas
analyzed based on results of three approaches (crack
initiation, crack propagation and arrest, stable crack
growth), allowing an evaluation of crack significance and
"fitnessforpurpose"assessment.
FULLSCALEMODELTESTING
Two fullscale pressure vessels, modeled as prototype of
thepenstockmoststressedpart(Fig.1),wereproducedof
SUMITEN 80P (SM 80P) HSLA steel, 47 mm thick plates,
"Sumitomo",Japan.Thebursttestwasperformedonpre
cracked model for testing resistance to fast fracture and
crack arrest properties. The hydropressure test on a
model with no crack enabled the postyield experimental
analysisofweldments,whichisthetopicofthispaper.All
weded joints were undermatched, meaning that yield
strenghtwaslowerthantheyieldstrengthofbasemetal.
Having also in mind the inevitable presence of residual
stressesandstrains,onecanexpectsignificantplasticityin
107
A.M. Mahdi, et al.
Quality Assurance of a Large Welded Penstock Manufacturing by Means of Full-scale Model Testing
the most stressed welded joints. From the purpose of

testing,anexperimentalmodelwasmadefromthecentral
section including the 5 angle, and was closed at the top
andbottominordertoapplytestpressure.Weldedseams
weremadeasautomatic(markedasLS1,LS2,LS3),except
for LM1 and CM which were done manually. Testing was
performed using various values of pressure. The first test
wasperformedforthepressureof9MPa,whichwasthen
decreasedto0,andonlyelasticdeformationwaspresent.
Following this test, additional strain gauge was added at
the place with highest stress concentration (strain gauge
34, Figure 2). The second test was performed with
pressure that started with 0 and was gradually increased
upto12.05MPa,andthendecreasedbackto0,andthis
time plastic strain also occurred at the welded section at
strain gauge 34. The results of the second test for the
above mentioned strain gauge are given in Tables 1 and,
for loading and unloading, respectively, along with the
diagraminFig.3.
Fig.3Pressurestraindiagram
DISCUSSION
The diagram in Fig. 3 shows elastic behaviour up to the
valueofapproximately9MPa,atwhichpointplasticityin
weld metal occurs. The stress increases until
approximately9.8MPa,afterwhichthebasemetaltakes
all the pressure (having much higher yield strength than
the weld [1]) and starts deforming elastically. Once it
reaches 12.05 MPa and is subsequently unloaded an
unusualbehaviourappearswhenpressureisreducedfrom
12.05to10.8MPa.Thisbehaviourisalmostparalleltothe
plastic part of the strain. Such a complex behaviour has
been noticed in other experiments, as described in [2].
Suggested explanation would be that because of
significantdifferenceinyieldstrengthsofmaterials,when
yieldstrengthofweldseamisreached,itstartstobuckle.
Atonepointplasticstrainbecomestoolargeandthebase
metalalsostartstodeformnoticeably.Whenthepressure
starts to decrease, we assume that elastic strain of the
basemetal(intheareaaroundtheweldedseam)startsto
behaveasaspringandstartstocompresstheweldmetal.
Below the pressure of 10.8 MPa, the base metal and the
weldedseamstartedbehavingasexpected.Moredetailed
analysis,includingnumericalsimulationbyusingthefinite
elementmethod,isgivenin[3].
Fig.1Thefullscalemodel
CONCLUSIONS
Thefullscalemodeltestinghasbeenusedasacrucialstep
in the quality assurance of a large welded penstock
manufacturing,inaccordancewithISO9000series,where
weldingisdefinedasaspecialprocesssinceweldscannot
be fully verified by subsequent inspection. By using a
sequance of increasing pressure, overall behaviour of the
large welded penstock has been verified, including
resistanceofweldments,astheweakestpoints,tocrack
likedefects.Morespecifically,themoststressedregionof
fullscale model, monitored by the SG 34, indicated
complex elasticplastic behaviour, which needs further
investigation, but in any case, verifies quality of welded
jointsandpenstockasalargeweldedconstruction.
Fig.2Positionofstraingaugesalongthecircumferenceof
themodel
REFERENCES
[1] S.Sedmak, A. Sedmak, Integrity of Penstock of
HydroelectricPowerplantStructualIntegrityandLife,
Vol.5,No2,2005,p.5970
[2] T. Adiev, A. Sedmak, G. Adiev, M. Arsi, Residual
Strength Assessment of Cracked Welded Spherical
StorageTankStructualIntegrityandLife,Vol.2,No1
2,2002,p.2022
[3] S.Sedmak, U. Tatic, A. Sedmak, A. Djurdjevic,
Numerical simulation of weldment behaviour during
fullscale testing of large penstock, accepted for
StructualIntegrityandLife,Vol.13,No.1,2013
Tab.1ResultsforStrainGauge34loading
Pressure(MPa) 0 0.5 2.95 7.35 9 9.8 10.8 11.5 12.05
Straininaxial
direction 445 534 1154 3026 3884 5355 5740 6131 6576
6
(x10 )
Tab.2ResultsforStrainGauge34unloading
Pressure(MPa) 12.05 10.8 9
7.35 2.95 0.5
0
Straininaxial
6529 5105 4583 4125 2899 2261 2172
6
direction(x10 )
108

TheProceedings
Procedure Development for Standardized Tooth Cavity Preparation

for in Vitro Research Purposes
MilosMilosevic1NenadMitrovic2AleksandarSedmak2DragicaManojlovic3NikolaMomcilovic2
VesnaMiletic3
1
InnovationCenterofFacultyofMechanicalEngineering,UniversityofBelgrade,KraljiceMarije16,11000Belgrade,Serbia
FacultyofMechanicalEngineering,UniversityofBelgrade,Belgrade,KraljiceMarije16,11000Belgrade,Serbia
SchoolofDentalMedicine,UniversityofBelgrade,Rankeova4,11000Belgrade,Serbia
2
3
ARTICLEINFO:
Abstract:
Dentalcomposites
Polymerizationshrinkage
Preparation
Toothcavity
All resin-based dental composites exhibit volumetric shrinkage during polymerization as one of the main
disadvantages. 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. For in vitro testing in
restorative dentistry, manual cavity preparation is mostly applied, even though it is difficult to maintain the same
cavity dimensions. Displayed procedures, equipment and machining regimes are practically applicable for various
cavity types and different tests in dental practice, where it is important to maintain the same cavity dimensions in
multiple teeth.
Citation:MiloseviM.,etal.: ProcedureDevelopmentforStandartizedToothCavityPreparationforinVitroResearchPurposes,2ndInternationalConferenceManufacturingEngineering
&Management2012,(2012),p.109112,ISBN9788055312163
INTRODUCTION
Currentlightcured,resinbasedcompositesofferexcellent
aesthetics, improved mechanical properties [1] and good
bonding to tooth structure, when placed in combination
with adhesive systems [2, 3]. However, all resinbased
materials exhibit volumetric shrinkage during
polymerization as one of the main disadvantages [48].
Movement and spatial arrangement of monomeric units
are responsible for this volumetric change during
polymerization. Polymerization shrinkage is associated
with polymerization stresses that may cause cusps
movement,enamelfractureandcrackedcusps,whichmay
result in microleakage and postoperative pain [911]. For
in vitro testing in restorative dentistry, manual cavity
preparationismostlyapplied,eventhoughitisdifficultto
maintain the same cavity dimensions. Mechanical cavity
preparation may also cause tooth fracture [12, 13].
Currently available literature shows that instruments for
mechanical cavity preparation are not often used. They
are used to analyze the influence of cavity preparation
design on fracture resistance of posterior Leucite
reinforcedceramicrestorations[12,13].Inthesestudies,
authors reported frequent fractures associated with
mechanical cavity preparation. Obtained cavities in this
paperwillbeusedinvitrotoanalyzefreepolymerization
shrinkage and shrinkage between the opposing cavity
wallsusingdigitalimagecorrelationmethod.Digitalimage
correlation method (DIC) is becoming a common method
indeterminingmechanicalpropertiesofbiomaterials[14
17]. Displayed procedures, equipment and machining
regimes are practically applicable for various cavity types
anddifferenttestsindentalpractice,whereitisimportant
tomaintainthesamecavitydimensionsinmultipleteeth.
speed diamond saw. The dimensions of the prepared

cavity are shown in Fig. 1. Preparation and processing of
allsampleswereperformedusingthesameprocedure.
Fig.1Dimensionsofthepreparedcavityinaplastictooth
For cavity preparation, 17 molars extracted for the

orthodonticpurposesand17plasticmolarswerechosen.
For material application and recording procedure, 15
extractedand15plasticmolarswereused.Plasticmolars
had exact same dimensions considering that they were
prefabricated (KaVo Dental GmbH, Biberach, Germany),
while extracted molars had similar dimensions.
Standardized cavities with the same dimensions were
preparedinallteeth(Fig.1).Eachtoothwasembeddedin
30 x 30 mm cold acrylic cubes, up to the enamel
cementumjunction(Fig.2).
MATERIALANDMETHOD
Milling and cutting of both plastic and extracted human
molars were performed in this paper in order to obtain
modifiedclassIIcavitiesofstandardizeddimensions.Tools
used in this procedure are a milling cutter (d1= 2mm,
radius form end mill, finishing teeth, centre cut, straight
shankinaccordancewithDIN1835B.)andacircularslow
Fig.2Extractedtoothembeddedinacrylic
109
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,LakeBluff,IL,USA;University),whereasthe
subsequentcavitypreparationwasperformedinamilling
machineLOLAHMC500(LOLAInstitute,Belgrade).
Processingofocclusalandproximaltoothsurfacesby
cutting
EachsamplewasmanuallypositionedintheIsomet4000
machineusingamechanicalstoppersothatthesideofthe
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
exposeflatdentin.
Cavitypreparationbymilling
After the occlusal and proximal surface cutting, samples
were fixed using a universal mechanical clamp (Fig. 4A)
andpreparedinHMC500machinewiththemillingcutter
(Fig.4B).
Fig.4ProcessingbyHMC500machine:A.Samplefixation
B.Positioningofmillingcutter
CuttingregimesontheHMC500machine:
the velocity of the auxiliary motion of the tool for
plasticteeth:60mm/min
the velocity of the auxiliary motion for extracted
teeth:5mm/min
the velocity of the rotation of the mill: 1500
round/min
cooling:circulationofcoolingliquid.
Thenumericalcontrolisbasedonautomaticcontrollingof
the machine workspace upon a predefined motion
pattern. The order of operations and movement of
machine parts was controlled by a defined program.
However,itwasnecessarytodefineazeropointforeach
extracted tooth due to slight differences in their
dimensions(G58).Thepositionofthesampleconsidering
thereferencepointontheHMC500machinewasdefined
by the zero point (G58) of the sample or by xn yn zn
coordinate(Fig.5).
Fig.3ProcessingatoothusingIsomet4000machine.
A.OcclusalsurfaceB.Proximalsurface
Themainmotionofthesawwastherotationalmotionof
thetooldefinedbythecuttingvelocityn[round/min].The
auxiliary motion was defined as the linear motion of the
toolperunitoftime[mm/min].
TheregimesofcuttingontheIsomet4000machine:
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:circulationofcoolingliquid.
Using a precise measuring gauge (precision up to
0.01mm),thesawwaspositionedtolightlytouchthemost
prominentpointofthetooth.Thatpointrepresentedthe
zeropointfordeterminingthedepthofthecutting.
Gradually increasing the depth is followed by visual
controlforthereasonofobtainingthenecessaryoptimal
surfaceofthemeasuringsamplethatislateroncontrolled
withthemovabledigitalgauge.Gradualincreaseincutting
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
digitalcaliper(precision0.01mm).
Fig.5DefiningthezeropointG58(N)usingreferenceaxes
ofthecavityinrelationtotheproximal(side)andocclusal
(top)surface
110
The zero coordinate xn defined the position of the

longitudinalaxisofthecavityykandpresentedthecentre
of the cavity. Coordinate yn defined the position of the
surfaceofthetoothparalleltotheaxisofthetoolandaxis
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
ofthetooluntilthecrossingofthecavityaxis(yk)withxk
axis,coordinateynuntilthefirstcontactwiththeocclusal
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
trajectoryofthemillingcutterisshownonFig.6.
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%)comparedtothedesireddimensionsofthedepthof
thecavity.Ifthetoolwereincontactwiththesamplethat
had irregular surface, further processing would open the
pulp chamber. Those teeth would be rejected and not
usedforanalysis.Inordertopreventtheseevents,itwas
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
occlusallywas2.6mmandproximally1.29mm.
CONCLUSION
Basedontheanalysispresentedinthispaper,theoptimal
number of passings and depth of cutting is proposed for
thepreparationofstandardizedcavityforinvitroresearch
purposes. The deviations in tooth processing can be
accidentalbutrarelysystematicandcannotbepredicted.
However,withthepropertechnologyandcuttingregime,
the deviations can be substantially reduced. During the
cuttingprocess,thedeviationsoccurperpendiculartothe
surfaces, while possible deviations during the milling
process are associated to the shape, position and
dimensions of cavity irregularities. For teeth that
exceededthechosentolerancelimits(5%),theadditional
process of reducing the minimal thickness of the layer
could be performed. Teeth with nonadjusted 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
thetoolwouldnotopenthepulpchamber.Obtainingthe
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.6Thetrajectoryofthemillingcutterinonepassing
Foreachsampleadifferentzeropoint(G58)wasdefined
duetothedifferencesindimensionsbetweensamples.All
samples were processed in two passings with the milling
cutter,sothatthedepthofcuttingwas1mmperpassing.
PROCESSINGCONTROL
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
meansofreducingtheminimalthicknessofthetooth.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.Adigitalcalliperwasusedtocontrolthedepth,
widthandlengthofthecavityaftermilling.Thedeviation
valuesdidnotexceed5%in comparisontothereference
dimensions.
REFERENCES
[1] Vojvodic, D., Kozak, D.; Serti, J.; Mehuli, K.; elebi,
A.,andKomar,D.,InfluenceofDepthAlignmentofE
Glass Fiber Reinforcements on Dental Base Polymer
Flexural Strength. Materials Testing, 2011. 53(9): p.
528535.
[2] Arola,D.,L.A.Galles,andM.F.Sarubin,Acomparison
of the mechanical behavior of posterior teeth with
amalgam and composite MOD restorations. J Dent,
2001.29(1):p.6373.
[3] Brackett, W.W., D.A. Covey, and H.A. St Germain, Jr.,
Oneyear clinical performance of a selfetching
adhesive in class V resin composites cured by two
methods.OperDent,2002.27(3):p.21822.
[4] Chiang, Y.C., Polymerization Shrinkage with Light
Initiated Dental Composites. Dissertation, LMU
Mnchen:FacultyofMedicine,2009.
[5] Weinmann, W., C. Thalacker, and R. Guggenberger,
Siloranes in dental composites. Dent Mater, 2005.
21(1):p.6874.
[6] Chuang, S.F., C.H. Chang, and T.Y. Chen, Spatially
resolvedassessmentsofcompositeshrinkageinMOD
restorations using a digitalimagecorrelation
technique.DentMater,2011.27(2):p.13443.
[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.
Acrylicwasnecessarytomixinexact1:1ratiooftheliquid
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
toaweaktoothacrylicconnection,difficultiestoposition
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
withhigherpercentageoftheliquidphase,thedimensions
ofthecavityincreasedby2%inallthreedirections(width,
depth, length of the cavity). The saw performed main
rotationalandauxiliary linearmotiontoensurecomplete
processing of the teeth. Changes in the saw direction
111
[8] Miletic, V., et al., Analysis of local shrinkage patterns

of selfadhering and flowable composites using 3D
digital image correlation. Quintessence International,
2011.42(9):p.797804.
[9] Ausiello, P., A. Apicella, and C.L. Davidson, Effect of
adhesive layer properties on stress distribution in
composite restorationsa 3D finite element analysis.
DentMater,2002.18(4):p.295303.
[10] Bouschlicher,M.R.,M.A.Vargas,andD.B.Boyer,Effect
ofcompositetype,lightintensity,configurationfactor
and laser polymerization on polymerization
contractionforces.AmJDent,1997.10(2):p.8896.
[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.JAmDentAssoc,1983.106(4):p.4757.
[12] Soares, C.J., et al., Fracture resistance of teeth
restored with indirectcomposite and ceramic inlay
systems.QuintessenceInt,2004.35(4):p.2816.
[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.421429.
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.3942.
Tanasic, I., et al., Optical Aspect of Deformation
Analysis in the BoneDenture Complex. Collegium
Antropologicum,2012.36(1):p.173178.
Sojic,L.T.,etal.,Compressivestrainsanddisplacement
inapartiallydentatelowerjawrehabilitatedwithtwo
different treatment modalities. Gerodontology, 2012.
29(2):p.e8517.
Mitrovic N., Milosevic, M., Sedmak A., Petrovic A.,
ProkicCvetkovic R, Application and Mode of
Operation of NonContact Stereometric Measuring
SystemofBiomaterials.FMETransactions,2011.39(2):
p.5560.

TheProceedings
6 DOF Thrust Vector Control Test Stand Based on Stewart Platform

Design
PredragMilo1NikolaDavidovi2BranislavJoji3oreBlagojevi4MarkoMilo5
1
PhDMechanicalEngineering,ResearchEngineer,EDePro,Belgrade,Serbia,email:predrag.milos@edepro.com
PhDMechanicalEngineering,ResearchEngineer,EDePro,Belgrade,Serbia,emai:nikola.davidovic@edepro.com
4
5
2
3
ARTICLEINFO:
Abstract:
Thrustvectorcontrol
Rocketmotortesting
Jettab
Stewartplatform
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:PredragM.,etal.: DOFThrustVectorControlTestStandBasedonStewartPlatformDesign,2ndInternationalConferenceManufacturingEngineering&Management 2012,

(2012),p.113121,ISBN9788055312163
NOMENCLATURE
Aeb
F
m
Fzrel.
Fyrel.
4.
Separate thrustproducing devices that are not part

ofthemainflowthroughthenozzle;
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
techniqueshavebeenusetoredirectthemotorthrustand
provide steering forces. Aerodynamic techniques have
demonstrated very rapid response rates, but also suffer
motorthrustlossesatlargeTVCvectorangles.Thehigher
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
thrusti.e.thehighertheTVCanglerequired,thelargerthe
percentageofthrustinvolved.Jettabsorvaneshavebeen
used for rapid thrust vector control steering, especially
earlyinflightwhenmissilespeedsaretoolowtoachieve
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 loware
rationozzles.Itsthrustlossishighwhentabsarerotated
atfullangleintothejet,butiszerowhenthetabsarein
their neutral position outside of the jet. On most flights
thetimeaveragedpositionofthetabisaverysmallangle
and the average thrust loss is small. Jet tabs can form a
verycompactmechanismandhavebeenusedsuccessfully
on tactical missiles. Four tabs, independently actuated,
rotatedinandoutofthemotorsexhaustjetduringrocket
motoroperationprovidecontrolavehiclespitch,yawand
roll motions. Side forces and roll torques are usually
relativelysmallcomparedtothemainthrustandthepitch
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.Inthispaperispresentednoveldesignof
6 degree of freedom thrust vector control test stand. His
verificationisperformedonmeasuringthrustvectorangle
deflectionandthrustlossesofjettabTVCconfigurationin
Relativenozzleexitareablockage
TotalimpulseofforceinZdirection(thrust)
TotalimpulseofforceinYdirection(sideforce)
Consumedmass
Relativelossofthrust
Relativesideforce
Deflectionangle
INTRODUCTION
In addition to providing a propulsive force to a flying
vehicle,arocketpropulsionsystemcanprovidemoments
torotatetheflyingvehicleandthusprovidecontrolofthe
vehicles attitude and flight path. By controlling the
direction of the thrust vectors through the various
mechanismsitispossibletocontrolavehiclespitch,yaw
and roll motions. Most tactical motors require some
steering to meet flight maneuvering requirements. In
additionto,orreplacing,traditionalexternalaerodynamic
control fins, steering control has been demonstrated by
deflecting the nozzles hot exhaust gases, or the motor
thrust.Effectivenessofthethrustvectorcontrolsystemsis
inversely proportional to the dynamic pressure. That
meansthateffectivenesswillbeincreasedwithdecreasing
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
bynozzletype,eitherfixedormovable,andsecondbythe
method of providing actual thrust vector control. TVC
mechanismscanbeclassifiedintofourcategories:
1. Mechanical deflection of the nozzle or thrust
chamber;
2. Insertion of heatresistant movable bodies into the
exhaustjet(suchasjetvane,jetavator,jet tab,axial
jetdeflector,domeddeflector);
3. Injectionoffluidintothesideofthedivergingnozzle
section, causing an asymmetrical distortion of the
supersonicexhaustflow;
113
P. Milo, 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
measureteststandresponseonexternalloads.
static conditions and results as a function of nozzle exit

areablockagepercentagearepresented.
TESTSTANDDESIGN
The test stand design originates from Stewart platform
designidea.AStewartplatformisatypeofparallelrobot
that incorporates six prismatic actuators, commonly
hydraulic jacks. These actuators are mounted in pairs to
the mechanism's base, crossing over to three mounting
pointsonatopplate.Devicesplacedonthetopplatecan
be moved in the six degrees of freedom in which it is
possible for a freelysuspended body to move. These are
the three linear movements x, y, z (lateral, longitudinal
andvertical),andthethreerotations:pitch,rollandyaw.
Theterm"sixaxis"platformisalsoused.
Fig.3Roddesign
In this case external loads will be thrust components of
rocketmotorwhichisfastenedtotheupperplate.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
forcesandpositionofactontoteststand,systemmustbe
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
calibrationmatrix(A).Ourtasknowistosolvesystemof6
simultaneouslinearequationusingmatrices.
AF=S
(1)
Where F is load matrix and S is matrix of test stand
response (values from load cells). The solution to the
systemofequationsisgivenby:
F=A^(1)S
(2)
WhereA1isinversematrixofmatrixA.
Fig.1ExampleofStewartplatformdesign
Unliketheoriginaldesignupperplatform isnotmovable,
because instead of six actuators are mounted six rigid
rods. Different loads acting on the top plate will produce
differentreactionsinroadsaccordingtothevectoroftheir
actions.
(3)
A preliminary analysis of the system was performed by

usageofsoftwarepackageNASTRAN.
Fig.2Teststanddesign
Lowerplateofteststandisconnectedtothebasementby
the rigid connectionsbolts. The upper plate is connected
tothelowerplatebysixrodsattachedtothebothplates
bythesphericalplainbearings.Onthatwaytheycanonly
transfer loads along their axis. Placement of load cells, in
Fig.4ModelofteststandloadedbyFx
114
P. Milo, et al.
Tab.2 Calibration matrix Ap4 with load cell placed on

position4
Mx
My
Fz
Fy
Loadcell
position1
0.20075016
1.8E06
0.177363362
0.07016276
Loadcell
position3
0.1003751
0.1738562
0.1773634
0.8791101
Loadcell
position5
0.1003752
0.1738526
0.17736336
0.8089484
Loadcell
position4
0.1003752
0.1738526
0.177363362
0.8089484
With condition number

16.471

position6
Mx
My
Fz
Fy
Fig.5Reactionsinrodsuponappliedload
By applying different loads we can obtain reactions on
those loads and thus build our calibration matrix A. As
mentioned earlier for measuring jet tab TVC system we
will use 4 load cells. This analysis will helps to make a
choice of the best possible location for load cells.
Obviously, three load cells have to be placed
symmetrically around the Z axis (rods 1, 3 and 5; or 2, 4
and6).Here,thefirstcombinationwillbeused,sothelast
fourthloadcellcouldbeplacedinpositions2,4and6.In
order to determinate which position is the best, first
calibration matrices have to be calculated for all three
cases, after which their condition numbers will be
calculated. Condition number of some matrix A is the
productoftwomatrixnorms.
cond A
norm A norm A
(4)
Condition number measures the sensitivity of a linear
systemsolutiontoerrorsininputvector.Aproblemwitha
lowconditionnumberissaidtobewellconditioned,while
a problem with a high condition number is said to be ill
conditioned. This number clarifies how accurate is
expected the vector x to be, when solving a system of
linear equations Ax=b. So, in solving the equation Ax=b,
the relative error in the solution, divided by the relative
error in the righthandside vector is given by the
condition number of A. The following rule of thumb is a
usefulwaytoexpresstheaboveestimate.Itstatesthatif
m=log10(cond(A))thenmisthenumberofdigitsaccuracy
lost in solving the system of equations Ax=b. There is
typically additional error due to the many calculations
needed in solving the equations. The estimate for
additionallossesisgivenbylog10(n)ifthematrixAisnxn.
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
resultsofsameaccuracy.
position2
Mx
My
Fz
Fy
Loadcell
position1
0.20075016
1.8E06
0.177363362
0.07016276
Loadcell
position3
0.1003751
0.1738562
0.1773634
0.879110

6.14 10
Loadcell
position5
0.1003752
0.1738526
0.17736336
0.8089484
Loadcell
position3
0.1003751
0.1738562
0.1773634
0.8791101
Loadcell
position5
0.1003752
0.1738526
0.17736336
0.8089484
Loadcell
position6
0.100375
0.173856
0.177363362
0.87911

16.92
Fig.6Teststandassembledinlaboratory
TESTSTANDCALIBRATION
In order to accurate calculate forces and moments it is
necessarytoperformprecisecalibrationoftheteststand.
Because of that special attention was paid to the
introduction of the deadweight loads on the test stand.
LoadinZdirectionwasappliedontheteststandoverreal
nozzle mounted on the test stand in the same way as it
was during firing test. Loads in X and Y direction were
appliedontheteststandoverspecialpulleyssystem(see
figure6)ontwodifferentelevation,alongZaxis.
Loadcell
position2
0.2007502
2E06
0.177363362
0.0701628
Fig.7Test stand
calibrationZaxis
115
Loadcell
position1
0.20075016
1.8E06
0.177363362
0.07016276
Fig.8Teststand
calibrationXaxis
P. Milo, et al.
As mentioned earlier in measuring jet tab TVC system 4

load cells were used and for that reason calibration was
performedfortwoforcesFzandFy,andtwomomentsMx
and My. For that, it is necessary to perform total of five
calibrations, 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). Miniature, stainless steel universal load cells,
with capability to measure in both tension/compression
directions, were built in test stand rods. Maximum
capacity is 5000N and accuracy is 0.25% FSO linearity,
hysteresis,repeatabilitycombined.
Fig.9TeststandcalibrationYaxis
Fig.11LoadcellcalibrationuponFx
Fig.10LoadcellcalibrationuponFz
Tab.4Loadcellshopes(inthiscalculationpositivesignisforcompression)
Fz
7103.15314
4963.95712
7143.11189
10238.3814
Channel0
Channel1
Channel2
Channel6
Fx(z=0)
947.72346
1123.11324
5566.77692
3915.2083
Fx(z=104.8)
1047.22485
954.0528
18997.51265
7375.997
Fy(z=0)
2889.59442
1399.16883
950.11116
1093.77388
Fy(z=105.5)
1968.24394
1666.23798
883.80964
1051.27911
Fy(z=0)
0.000346069
0.00071471
0.001052508
0.000914266
Fy(z=105.5)
0.000508067
0.000600154
0.001131465
0.000951222
Tab.5Calibrationmatrix(inthiscalculationpositivesignisforcompression)
Channel0
Channel1
Channel2
Channel6
Fz
0.000140783
0.000201452
0.000139995
9.76717E05
Fx(z=0)
0.00105516
0.000890382
0.000179637
0.000255414
Fx(z=104.8)
0.000954905
0.00104816
5.2638E05
0.000135575
Reaction in rods (load cells) for applied unity forces (reciprocal values of slopes). Now is possible to create matrix A for calculation of
appliedforces.
Tab.6Calibrationmatrix(inthiscalculationpositivesignisforcompression)
Fz
0.000140783
0.000201452
0.000139995
9.76717E05
Channel0
Channel1
Channel2
Channel6
Fy
0.000346069
0.00071471
0.001052508
0.000914266
Mx
1.53552E06
1.08584E06
7.48407E07
3.50298E07
My
9.56635E07
1.50551E06
1.21182E06
1.14351E06
Channel2
2994.24708
121.232781
23075.9609
359749.6158
Channel6
1160.905159
650.3075106
24915.4628
446089.6077
Tab.7Inversematrixofcalibrationmatrixforcalculation
Fz
Fy
Mx
My
Channel0
2430.347703
50.25577932
437828.7634
33282.36543
Channel1
1747.597754
364.4213669
277855.4864
56978.29029
M
M
.
.
(5)
(6)
To calculate loads according to the applied forces, an

inversematrixofmatrixAe.i.matrixA1mustbefound.
116
P. Milo, et al.
ROCKET MOTOR
Rocket motor (RM) used for testing, was of a slotted
propellant grain configuration. Length of slots was tailored
to provide neutral burning (pressure and thrust versus
time are almost without changes - neutral). Graphite
nozzle throat was used in order to eliminate throat
erosion. Exit diameter of nozzle is 47mm, the expansion
ratio is 5 and half divergent angle is 20 degrees. To the exit
nozzle surface is possible to attach different obstacles
(tabs) in order to block desired percentage of exit area.
Tabs are made from molybdenum to withstand thermal
loads. Propellant used in test is thermo-plastics composite
propellant with 1.5% of aluminum powder. Total pressure
in nozzle was also measured during motor burning time.
Fig.15 RM during firing
Fig.16 Nozzle after test

Aeb=20%
TEST RESULTS
First test was without any tab. This test will be used as a
benchmark, to compare these results with other tests
results in which variant percentage of the nozzle exit area
were blocked. It is also known that, in this first test, side
force must be zero. Thus if some other result was to be
obtained that would be a signal that, something went
wrong for sure. Results are presented in following figures
17 and 18.
Fig.12 Rocket motor nozzle cross section
Fig.17 Pressure vs. time
Fig.13 Nozzle exit surface and used tabs geometry
Fig.18 Thrust and side force vs. time

Test stand is of vertical type, thus consumed propellant
mass should have some influence on results and has to be
incorporated in calculation. Measuring of pressure vs. time
can help in that. First the characteristic velocity, needs to
be calculated by using formula:
Fig.14 RM before firing
117
P. Milo, et al.
Total impulse of side force is negligible so it can be

claimed that the observed system works correctly in this
case.FrommeasuredMxandMymomentsitispossibleto
calculate position of thrust vector in XY plane, rightly
assuming that side force in X axis direction is zero.
Applyingmomentequationsisobtained:
x=M_y/F_z
(9)
y=(M_x+zF_y)/F_z
(10)
(7)
after that it is possible to calculate how much propellant

massisconsumedoveranytimeintervalbyusingformula:
(8)
Consumed mass from time zero up to current time in

calculationshouldbeaddedtothevalueofZforceinthat
momenttogetarealforceinZdirection,socalledFztotal.
Fig.19Xpositionofresulttrustvs.time
Exitnozzleareablockageof5%
Fig.20Ypositionofresulttrustvs.time
Fig.21Thrustandsideforcevs.time
Fig.22Deflectionanglevs.time
118
P. Milo, et al.
119
P. Milo, et al.
arctg
%
%
(11)
(12)
(13)
CONCLUSION
Regardlessofthefactthatformeasurementofpresented
single and not movable jet tab TVC system it is not
necessary to have test stand with more than 2 DOF
(becausepositioninspaceofjettabisknownandremain
invariable) up to 4 load cells were used. The reason for
that is to validate results and to prove the concept. By
comparing the obtained results to the other published
results and some theoretical models, 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. Although this study only outlines the
resultsoftestswithjettab,thisteststandcanbeusedfor
testing other TVCs systems in both: static and dynamic
conditions. Excellent results of testing domed deflector
TVC system in dynamic conditions were obtained. Design
and manufacturing of presented test stand is very simple
and doesnt require special precision. Even an inaccurate
symmetry of the test stand (all rods are not at the same
angletothebottomor/andupperplate)doesnotpresent
a problem, because by calibration the exact test stand
responsecanbeobtained,andthatisthemostimportant.
Fig.37 Test results as a function of relative nozzle exit

areablockage
Tab.8Summaryresults
Aeb
Fz
Fyrel.
5.6
9.9
19.9
26.5
3.2
5.7
11.9
17.0
rel.
%
0
5
10
20
30
Ns
3999.6
3988.7
3907.4
3715.6
3459.9
Ns
225.2
392.5
784.3
1059.6
Kg
2.070
2.070
2.055
2.045
2.070
0.3
1.6
6.0
13.5
120
P. Milo, et al.
Acknowledgement
REFERENCES

35044).
[1] Paul Zarchan, Editor in Chief: Tactical Missile

Propulsion, Volume 170 Progres in Astronautics and
Aeronautics, American Intitute of Aeronautics and
Astronautics,Inc,1996.
[2] George P. Sutton, Oscar Bilbarz: Rocket Propulsion
Elements 7th edition, A WileyIntersience
Publication,2000
[3] B.Joji. .Blagojevi,V.Fotev,M.Marko and others:
Rocket propulsion researchthrust vector control, Jet
Propulsion Laboratory Faculty of Mechanical
EngineeringUniversityofBelgrade,19841986.
[4] R.G.Eatough: Improved jet tab thrust vector control
for the BGM34C booster, Final report AFRPL TR77
49,May1975June1977.
121

TheProceedings
Comparison of Complexity Indicators for Assessing General

Process Structures
VladimirModrk1DavidMarton1SlavomrBednr1
1
DepartmentofManufacturingManagement,TechnicalUniversityofKosice,FacultyofManufacturingTechnologieswithseatinPresov,Bayerova1,Slovakia,
vladimir.modrak@tuke.sk
ARTICLEINFO:
Abstract:
Complexity
Structure
Graphtheory
Vertexdegree
This paper focuses on the comparison of different complexity indicators for complexity assessment of selected
general process structures. The main objective in this study is to test their ability to uncover assumed differences in
structural complexity among observed general process structures. The obtained results of this theoretical study
show that all proposed indicators can be effectively used for analyzing structural complexity of general process
structures.
Citation:ModrkV,MartonD,BednrS. ComparisonofComplexityIndicatorsforAssessingGeneralProcessStructures,2ndInternationalConferenceManufacturingEngineering&
Management2012,(2012),p.122125,ISBN 9788055312163
INTRODUCTION
comparison with other known approaches. Obviously
there are other literature sources discussing the issue of
process complexity from different angles of view (see for
example[9],[10],[11]).
Nowadays, it is useful and important to manage process

structuresandtomeasuretheircomplexity.Thisisoneof
thereasonsofanincreasingnumberofresearchworkson
complexity of manufacturing process structures. On the
otherhandaunifiedprocedureforcomplexityassessment
of process structures is still missing. Moreover, the
tendencies and relations in the development of
organizational, management and production structures
increase the requirements concerning the characteristics
of the process structures. In order to obtain the
relationship,asetofcomplexityindicatorsistested.
METHODOLOGY
GraphTheory
One of the useful methods for evaluation of structural
properties of manufacturing processes is a graph theory.
The fundamental concept of a graph theory is the graph
G=(V;E)thatconceptuallyconsistsofasetofverticesV(G)
and edges E(G). The two points connected by a line are
said to be adjacent. Two lines that share an endpoint of
thegraphareincident.
In the proposed approach the structural properties of
manufacturingprocesswillbeexaminedintermstowhich
theprimaryelementsoftheprocessstructure:vertices(or
nodesdenotesbyN)andedges(oflinksdenotesbyL)are
subjected. In this research all initial parameters of the
examined process graphs (see fig.1) are know with
certainty, so that the problem is deterministic. The
primary research methodology has been based on the
applicationofgeneralaxiomsofgraphtheoryforselected
problemarea.
Spearmanrankordercorrelation
To gain some insight into the relation between the
properties of the individual parameters under the given
conditions,statisticalanalysiswasperformed.Inclassical
statistical tests, such as the use of a single correlation
coefficientrcbetweentworandomvariables,itisrequired
thattherandomvariablesarenormallydistributed.Under
the assumption of Gaussian violation (as in our case),
nonparametric Spearman's rank order correlation
(corrected) is calculated. The obtained values of the
correlation coefficients are summarized in Table 2.
CorrectedSpearmancorrelationcoefficientisformalized:
LITERATUREREVIEW
Current research on process structures` complexity is
characterizedbydifferentwaysofcomplexityexploration.
Itispossibletoidentifythefollowingresearchareas:
(i) Theoretical discussions of production systems
complexity. They are primarily based on the systems
theory or mathematical modeling of a structure.
Simulation and nonlinear dynamics is are used to gain
data for the structure`s analysis [1]. Another relevant
approach to the complexity measurement is based on
graphtheory(seeforexample[2]).
(ii)Measurementsofsystemcomplexityandloweringthe
complexity of a system. There is a link between the
complexity and the performance of the same system [3].
Mostly used key words in context of measuring methods
are: number of elements of the structure, manageability.
Casestudieshavemostlybeenbasedonframeworks.Itis
necessary to decrease the complexities of production
structures especially for planning and work distribution
probleminthehighvarietysystems.Noneofthesestudies
solvedtheproblemadequately[4].
(iii) Relation between process structure complexity
measurement and process performance measurement. It
is clear that the complexity is an important factor
determiningtheproductionsystem`squalityandtherefore
process complexity is connected with its performance.
Differentaspectsofbusinessperformancemeasurements
and control were discussed, for example, in [5] or [6].
Taking in mind the need for process structure
simplification, an Average Shortest Path (ASP) and a
ModifiedFlowComplexity(MFC)havebeenextendedand
presented[7],[8].Wewillusetheindicatorinthisstudyin
rC
i 1
C x .C y
122
C x C y d i2
CX
n n
Tx
12
,
(1)
(2)
Comparison of Complexity Indicators for Assessing General Process Structures
Cy
d R( xi ) R( yi )
n
n3 n
Ty
12
,
i 1
(3)
(4)
i1
TX
t3 t
12 ,
(5)
Ty
t t
12 ,
(6)
chosen, and coefficients. Nodes are counted only

once, even if they are repeated in Tiers. Presence of
repetitionisincludedinLinkscount.
2
i
V. Modrak, D. Marton, S. Bednar
RestrictivenessestimatorRT
RT is practically the same measure as Order Strength
defined by Mastor [13]. 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, such
that rij=1 if there is a path from the vertex vi to vj,
otherwiserij=0,andNisanumberofnodesinagraph.RT
rangesfrom0to1,wherethezeroisforparalleldirected
graphsand1forseriesdirectedgraphs.
AggregatecomplexityindicatorAC
Inordertomeasurestructuralcomplexityofsupplychains
itseemstobeusefultoapplyACindicatorconstructedby
Modrak [13]. A concept of this indicator is based on the
aggregation of three subindicators: Binding of structure
(B),Structurediversity(SD)aDiameterofnetwork(D).The
followingexpressionforanAggregatecomplexityindicator
isformulated:
n2
j 1
(10)
MFC T N L ,
(14)
TN N
MTI
T 1 N ,
(15)
MTR
TN
N ,
(16)
H W W log 2 W wi log 2 wi
i 1
(18)
Sincethemaximumentropyiswhenallwi=1,then
D max ij ( Dij )
(11)
inwhich:
N1,N2arenumbersofinitialandfinalnodes,
cijrepresentsnumberofheterogeneouspathstheith
input node to the jth output node of the graph
(without any possibility to pass twice through the
samenodewithinoneroute),
Dijistheshortestpathbetweeniandj.
AverageshortestlengthASP
The ASP is a network indicator which is applicable for
determinationdistanceofnetworkbetweeneverypairsof
nodes.AlexandEfstathiou[7]useditforinterpretationof
robustness complex networks as fragmentation of
network.Formallycanbedescribedasfollows:
1
(12)
ASP
. d ij .
N .( N 1)
Where:
dijistheshortestpathinthenetworkforallnodesfromi
tillj.
FlowcomplexityFC
TheFCisproposedbyCrippa[14].Itcanbeexpressedby
(13) and it counts all Tiers (including Tier 0), Nodes and
Links and adds all these counts, weighted with arbitrary
H max W log 2 W .
(19)
By substituting W=deg(v)i and wi = deg(v)i, the

informationcontentofthevertexdegreedistributionofa
network called as Vertex degree index (Ivd) is derived by
BonchevandBuck[15]thatisexpressedasfollows:
V
I vd degv i log 2 degv i

i 1
(20)
COMPARISONOFCOMPLEXITYINDICATORS
Representingofmanufacturingprocessstructures
In order to assess the relevance of the compared
complexity indicators for the selected complexities of
manufacturingprocessstructurestheyhavebeenassessed
for a set of graphs. For this purpose we selected 10
modelsthatareshowninFig.1.
123
i 1 j 1
s 1
(17)
Where:NNumberofNodes,TNNumberofNodesperi
thTierLevel,LNumberofLinks,LKNumberofLinksper
ithTierLevel,TNumberofTiers.
VertexdegreeindexIvd
TheinformationentropyofagraphwithatotalweightW
andvertexweightswicanbeexpressedintheformofthe
equation:
cij 1
i 1
LK
MLR
L
AC log(( B SD D / 3 )) . (8)
Where:
L
B
1
N 1 ,
(9)
1 n1
SD
N1 N 2 i1
(13)
Where:TiithTier,NssthNode,LKithandjthLink.
ModifiedflowcomplexityMFC
Modified flow complexity indicator [8] combines FC
togetherwithMultiTierratio(MTR)andindex(MTI),and
MultiLink ratio (MLR). Using MTI, MTR and MLR we can
determine, and coefficients. MFC basically counts all
Tiers(includingTier0),NodesandLinksandaddsallthese
counts, weighted with determined, and coefficients.
InMFCindicator,NodesandLinksarecountedonlyonce,
eveniftheyarerepeatedingraph.PresenceofNodesand
Links repetition is included in coefficients. In
mathematicallyterm,theMFCindicatorcanbeexpressed
asfollows:
DESCRIPTIONOFCOMPAREDCMPLEXITY
INDICATORSFORMANUFACTURINGSYSTEMS
RT
FC Ti N s LKij
Fig.1 Representation of Kaimanns process structures

(adoptedfrom[9])
RT
AC
ASP
3.5
3
2.5
Resultsofcomputationalexperiments
Table 1 shows the results of the implementation of
compared complexity indicators that were described
above. All selected models of manufacturing processes
whichispresentedinTable1arelistedinascendingorder
basedontheindicatorIvd.
2
1.5
1
0.5
0
Tab.1Resultsofcomparedindicators
NO.
RT
AC
ASP
FC
Fig.2ComparisonofAC,RT,andASP
MFC
Ivd
350
Graph10
0.99 0.82 3.6
53.00 45.05
45.51
300
Graph1
0.30 0.48 0.7
54.00 46.05
49.51
250
Graph2
0.52 0.73
59.00 51.05
71.28
Graph9
0.88 1.26 1.9
60.00 52.05
84.4
Graph8
0.78 1.13 1.4
62.00 54.05
89.91
Graph7
0.63 0.99 1.1
61.00 53.05
90.4
Graph3
0.61 1.21
65.00 57.05
113.8
Graph4
0.79 1.83 1.2
71.00 63.05
158.7
Graph5
0.88 2.59 1.2
78.00 70.05
201.1
Graph6
0.99 2.88 1.3
94.00 86.05
318.7
FC
MFC
Ivd
200
150
100
50
0
Fig.3ComparisonofIvd,MFCandFC
The obtained values of correlation coefficients are
summarized in Table 2. Statistically, a significant positive
correlation was found between variables Ivd and MFC.
However, sometimes the correlation coefficient may not
necessarily express the true causal relationship between
twovariables.
The graphs in Fig. 2 and Fig. 3 show that in spite of

different concept of the paired indices, they generate
comparableresults.
Toidentifymutualcorrelationamongrespectivevaluesof
testingindicators,Fig.4offersscatterplotsandrcsquared
values. Based on these results we can state that both
novel indicators, namely AC and MFC are comparable
measures with the existing indicators and are usable to
measure structural complexity of manufacturing
processes.
124
granted by the Ministry of Education of the Slovak

Republic.
Tab.2TheresultsofSpearmancorrelationcoefficients
No.
1
2
3
4
5
6
Correlation
Between
RT,AC
RT,ASP
AC,ASP
Ivd,MFC
Ivd,FC
MFC,FC
CorrectedSpearman
coefficient
0.646
0.872
0.406
0.988
0.988
1
REFERENCES
[1] Wiendhal, H.P., Scheffczyk, H. Simulation based
analysis of complex production systems with
methods of nonlinear dynamics. CIRP Annals
Manufacturing Technology, 1999, vol.48, pp. 357
360.
[2] Borgatti, S.P., Everett, M.G. A graphtheoretic
perspectiveoncentrality.SocietyNetworks,2006vol.
28,pp.466484.
[3] ElMaraghy, H.A., Kuzgunkaya, O., Urbanic, R.J.
Manufacturing systems configuration Complexity.
CIRPAnnalsManufacturingTechnology,2005,vol.54,
pp.445450.
[4] Brauner,N.,Crama,Y.,Grigoriev,A.,Klundert,vande
J.Multiplicityandcomplexityissuesincontemporary
production scheduling. Statistica Neerlandica, 2007
vol.61,pp.7591.
[5] Bucki, R., Chramcov, B. Controlth of the serial
production systems. WSEAS 13 International
Conference on Automatic Control, Modelling and
Simulation,WSEASPress,2011,pp.352356.
[6] Akkermans, H.A., Bogerd, P., Vos. Virtuous and
vicious cycles on the road towards international
supply chain management. International Journal of
Operations and Production Management, 1999, vol.
19,pp.565581.
[7] Alex, K.S.Ng., Efstathiou, J. Structural Robustness of
Complex Networks. Physical Review, 2066, vol.3, pp.
175188.
[8] Modrak, V., Marton, D. Complexity Metrics for
Assembly Supply Chains: A Comparative Study.
PhysicsProcedia,2012,inpress.
[9] LatvaKoivisto, A. Finding a complexity measure for
businessprocessmodels.ResearchReport,2001,pp.
125.
[10] Kaimann, R.A. Coefficient of network complexity:
Erratum. Management Science, 1974, vol. 21, no. 2,
pp.172177.
[11] Kuzgunkaya, O., ElMaraghy, H.A. Assessing the
structural complexity of manufacturing systems
configurations. International Journal of Flexible
ManufacturingSystems,2006,vol.18,pp.145171.
[12] Mastor, A. A., An experimental investigation and
comparative evaluation of production line balancing
techniques. Management Science, vol. 16, pp. 728
746,1970.
[13] Modrak, V. Comparison of process structure
complexity in manufacturing before and after
redesign. INCOM 2006 12th Symposium Information
Control Problems in Manufacturing, Preprints, 2006,
vol.2,pp.467472
[14] Crippa, R., Bertacci, N., Larghi, L. Representing and
measuring flow complexity in the extended
enterprise: the D4G approach. RIRL 6th International
Congress of Research and Logistics, 2006, pp. 231
242.
[15] Bonchev, D., Buck, G.A. Quantitative measures of
networkcomplexity.ComplexityinChemistry,Biology
and Ecology, vol. 1, Bonchev, D., Rouvray, D.H. Eds.
Springer,2005,pp.191235.
Fig.3Mutualcomparisonsofusedindicators
RESULTS
This study showed that developed indices are usable for
assessingthegivenattributeincasewewanttocomparea
staticcomplexityofdifferentprocessstructures.Itiswell
known that the Graph theory is useful for modeling and
analyzing a variety of empirical systems including general
process structures, 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. It is because the nodes and links consist of
different entities that interact in a network. This paper
also supports the need for parallel use of alternative
indicators to be used as a basis for a development of
objectiveevaluationofprocessstructuralproperties.
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, (no. 054TUKE4/2012)
125

TheProceedings
Unusual Possibility Research of Wear Resistance Increase in

Sphere of Soil Processing Tools
MiroslavMller1RostislavChotborsk2
1
FacultyofEngineering,CzechUniversityofLifeSciences,Prague,CzechRepublic,Email:muller@tf.czu.cz
FacultyofEngineering,CzechUniversityofLifeSciences,Prague,CzechRepublic,Email:choteborsky@tf.czu.cz
ARTICLEINFO:
Abstract:
Adhesivebond
Ceramics
Shearimpactstrength
Wearresistance
Machine,equipments andtheirpartialsegmentsworkingunderconditionsoftheagricultureareexposedto
an intensive abrasive wear, namely in a sphere of the soil processing. Important producers of the
agricultural machine use sintered carbides, namely the tungsten carbide in the soil processing tools. The
alternative to this solution is introducing the ceramic materials which have proved their positive wear
resistance.Thispaperdealswiththeapplicationpossibilityoftheceramic materialsandadhesivesinthe
sphere of the tools processing the soil. 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 ceramics Al2O3 was tested. 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. Applying this solution demands coping with the adhesive
bondingtechnologyoffirmandstrengthbondsthatmeanstheinteractionceramics/steel.
Citation: MllerM,ChotborskR.UnusualPossibilityResearchofWearResistanceIncreaseinSphereofSoilProcessingTools,2ndInternationalConferenceManufacturingEngineering
&Management2012,(2012),p.126131,ISBN 9788055312163
INTRODUCTION
tothee.g.thetungstencarbide.However,whenthesoil
processing,significanttoolwearoccurswhichisconnected
with the wastage of this tool. Microscopic particles get
unbarred into the soil and the tungsten carbide can
contaminate the soil when it is applied. A similar
problematic tendency can be observed at hard overlays
containing the chromium, vanadium and tungsten. This
factleadstothenecessitytotakeintoregardalsothesoil
chemistry when solving the wear resistance. The
effectivityofhighchromeoverlaysisinvestigatedbymany
authors, e.g. Chotborsk et al. [5]. When processing the
soil it is necessary to take into regard also the impact
dynamicpointofviewthatmeansthematerialtoughness
whichaffecttheintegrityofnotonlythesurfacelayersin
the negative way. Among unusual ways of increasing the
wear resistance ranks the application of the technical
ceramics and so creation of new functional surfaces. The
problematicaspectisnotthesufficientwearresistanceof
the tool, but its fragility. When soil processing the
essentialpointofviewisnamelythedynamicbehaviourof
thewholesystemincontactwiththesoil.Suchneketal.
states that Al2O3 and ZrO2 are suitable as the ceramic
materials exposed to the conditions of the intensive
abrasion[12].Carriedoutexperimentswiththedryrubber
wheeltestASTMG65provedthattestedoxideceramicsis
ofthesamewearresistanceasWCNiCrandCr3C2.The
high wear resistance is explained with very uniform
microstructurewiththesmallvolumeofglassyphase.Also
Medvedovskifoundoutsimilarconclusions.Hestatesthe
laboratory test results of various ceramic materials [6].
Stated values of the wear are tested in accordance with
ASTM B611 and ASTM G65. Suchnek states the
fundamental knowledge in his book that the higher
toughness and higher hardness the ceramic material is,
the better is its wear resistance under conditions of the
abrasive wear [12]. This statement is not valid for metals
at which the increased wear resistance and hardness are
often reached of detriment to lower fracture toughness.
Thepaperpresentstheresultsoftheresearchfocusedon
using the adhesive bonding technology as the possible
A complexity and a sustainability of systems in the

agriculture are key factors, namely in an integration with
keeping an ability to secure aliment and connected food
stuffproduction.Oneofmeansreachingthesustainability
inthesphereofthefoodproductioncanbeaconventional
soil processing. Machines, equipments and their partial
segmentsworkingunderconditionsoftheagricultureare
exposed to an intensive abrasive wear, namely in the
sphere of the soil processing. Regarding the wear
conditionsandtheprocessintensityareanintegralpartof
a lifetime and reliability not only of tools, but also the
whole systems. Currently many experts deal with the
problemsofincreasingthelifetimeofsegmentsprocessing
thesoil[1,4,8,9,10].Bothproducersofmachinesforthe
soil processing and also many research institutes all over
the world deal with the intensive research. The research
aimofvariousworkinggroupscanbedefinedasfollowing:
findingsuitablematerialsandmethodsfortheproduction
of optimum tools whose mechanical properties would
extend the tools lifetime and they would decrease the
energeticconsumptionofthesoilprocessingowingtothe
lower resistance. The possible solution is a creation of
bimetallic tools on one hand and various additional
materials on the other hand. Bonding methods are the
defined problem of various materials. Currently are used
the brazing and soldering. However, this method is
expensive and it cannot be applied in all cases. An
adhesivebondingisthegeneralbondingtechnologywhich
enablestobondheterogeneousmaterialsineffectiveway.
This technology is not innovated in the field of bonding
toolsforthemoment.Thetoolwearcanbedecreasedby
used high wear resistance material. The wear resistance
increasingofthesoilprocessingtoolsleadstotheincrease
of the tool lifetime and to the decrease of the energetic
consumption demands. Above mentioned presumption
defines explicitly the priority of research of the wear
resistanceincreasepossibilities.Sinteredcarbidesarethe
most widespread cutting material these days. Important
producers of exchangeable parts of the soil processing
machinesincreasethewearresistanceoftheirtoolsowing
126
Unusual Possibility Research of Wear Resistance Increase in Sphere of Soil Processing Tools
way for bonding or securing various accessory materials

distinguishedforincreasedwearresistance.Thetoolwear
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.Thenitispossibletospeakabouttheconstructional
solution which requires to find suitable bonding
technology. The disadvantage of the adhesive bonding
technology is namely low impact strength. This fact is
essentialintheapplicationinthesphereofexchangeable
wear parts processing the soil. The integral part of the
research work is the evaluation of not only the own
impact strength, but also the temperature affecting the
adhesive.Theresearchaimistoevaluatethepossibilityof
ceramic materials application as the potential wear
resistantmaterialinthesphereofthesoilprocessing.The
applicationofthissolutionrequiresknowingtheadhesive
bonding technology in the sphere of firm and sufficiently
toughness bond that means the interaction
ceramics/steel.
TwocomponentepoxyadhesiveUHUPlusendfest
epoxy300(UHU300),
Twocomponentepoxyadhesive3TONEpoxy
adhesive30min(3TON),
MetylmethacrylatNovatit(NMET),
MetylmethacrylatUHUplusmultifest(UHUM),
PolyesterMTB(MTB),
Adhesivebasedon
aminoetylaminopropyltrimetoxysilanNovatmel(N
tmel),
CyanoacrylateadhesiveNovax(NK),
Polymericparticlecompositesystemmatrix:two
componentepoxyadhesiveLepox1200,fillerinform
ofrubber(KLP).
Itisessentialtoobservethetemperatureinfluenceduring
the laboratory tests focused on the soil processing. The
reason is the friction during the soil processing which
increases the temperature of the tool. Many adhesives
resist very little against the dynamic loading, namely
impacts loading. The experimental research helps to find
limitsandpossibilitiesoftheadhesivebondingtechnology
andtoconfirmorrefutepresumedhypothesesnecessary
before application in series. In the technical practice the
impact strength is set by the Charpy method on the
impacthammer[3].Forsettingshearimpactstrengthitis
suitabletousetheimpacthammer,butitisnecessaryto
use different tester. However, this tester is not the in
supplyofthetestedequipmentandithastobedesigned.
The suggestion and design of the equipment for the
evaluationoftheshearimpactstrengthofadhesivebonds
werethesubjectoftheutilitypatternno.CZ23585U1[7].
The subject of the utility pattern is the tester for the
evaluationoftheshearimpactstrengthofadhesivebonds.
The equipment is composed of two parts, the impact
hammer and the equipment part for fixing the tested
sample. 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 technical
solutionisvisibleinfig.1andfig.2.
METHODOLOGY
An untraditional material applied on the soil processing
toolsisthetechnicalceramicsdistinguishedforhighwear
resistance.CeramicplatesbasedonAl2O3(92and96%)of
sizes 25 x 25 x 6 mm were tested. Ceramic plates were
adhesive bonded with the epoxy adhesive to the basic
materialsteel(S235J0).Theadhesivebondedsurfaceof
the ceramic plate was not mechanically nor chemically
treated.Theadhesivebondedsteelsurfacewaserodedby
Al2O3ofthefractionsizeF80andconsequentlychemically
cleaned.Onegroupofsampleswasnotadhesivebonded
to the basic material but it was fixed by means of locks.
Tests were carried out according to modified Charpy test
validformetalmaterialswith25Jimpacthammer[2].The
modificationconsistedinthefactthattherewasnotkerf
on the impact area of the ceramic plate. The impact
hammerfellon thelevelareaoftheceramicplatewhich
was adhesive bonded to the steel basic material. The
adhesivelayerthickness0.650.05mmwasthesamefor
all tests. The testing process carried out at the
temperatures 22 2 C and 100 2 C. The tests were
carriedoutin20cyclesthatmeansinrepeatedimpactof
the impact hammer working part until the first
discontinuitiesinsurfacelayersoccurred(speed14kmper
hour). Then the shear impact strength of adhesive bonds
(steel/steel,bottomsizesofthesample45x25x20mm,
uppersize25x25x10mm)wastestedwhichsimulatesin
effective way the conditions of presumed loading in
practicalapplicationthatmeansinthesoilprocessing.The
laboratorytestcourseisdescribedinthestandardCSNEN
ISO 965 which states mainly the shape and sizes of the
tested samples [3]. However, the suitable constructional
setting of the tested equipment is not defined. Adhesive
bondswereleftinthelaboratoryconditions(temperature
222C)forhardeningfor48hours.Testingwascarried
outondevelopedequipmentattemperatures20C,60C
and100C(temperatures60Cand100Cwerereached
in the laboratory chamber). Following adhesives were
tested: Adhesives based on twocomponent epoxy
adhesives,
metylmethacrylates,
based
on
aminoetylaminopropyltrimetoxysilan,
polyester,
cyanoacrylates and the polymeric particle composite
system (matrix epoxy adhesive, filler rubber). The
following list presents the identification of tested
adhesivesandtheiridentificationwhichisusedintextfor
bettercleararrangement:
TwocomponentepoxyadhesiveLoctiteNordbak
7256(LN7256),
TwocomponentepoxyadhesiveLepox1200(L1200),
Fig.1 Apparatus for testing shear impact strength of

adhesivebondsfixedinCharpyhammer.
Fig.2Impacthammerfortestingshearimpactstrengthof
adhesivebondsfixedinCharpyhammer.
127
M. Mller, R. Chotborsk
Fromtheexperimentresultsitwasabletoclaimthatthe
ceramicsissuitablewearresistantmaterial.Itwasdefined
aproblemintheboundarylineoftheadhesivelayerwhich
has to be solved. It was tested a few types and sorts of
adhesives(epoxyadhesive,acrylate,methylmethacrylate,
cyanoacrylates).
TESTRESULTS
TestingofceramicplatesbasedonAl2O3(92%and96%)
ofthickness6mm,impactenergy25J,temperatures22
2 C and 100 2 C. Tested ceramic plates without the
layer of the adhesive were completely broken during the
first impact (fig. 3). Tested ceramic plates were fixed by
meansoflockstothesteelbasicmaterial.Ceramicplates
based on Al2O3 showed the ability to resist against this
dynamicloading25Jattheimpactspeed14kmperhour
butonlyincaseofusingtheadhesivebondingtechnology.
The number of repeating cycles was 20. It was occurred
onlyminorfailurevisibleinfig.4.Afterreaching20cycles
oftheCharpyhammerimpactitcametothedelamination
in the adhesive layer and consequently to gradual
destructionoftheceramicplate(fig.5).
Adhesivesbehaveddifferentlyduringtesting
Forapplicationatthesoilprocessingnamelythegroupof
adhesives distinguished for increasing or constant shear
impact strength of adhesive bonds with increasing
temperatureisimportant.Whenevaluatingthetestedset
of various adhesives it was evaluated great difference in
reachedvalueswhichwereinintervalfrom3440to18360
J.m2. When testing boundary ceramics/steel the mean
value was at the adhesive NMET and at the laboratory
temperature6360578J.m2.Whencomparingthesame
adhesiveintheboundarysteel/steelthevaluewasatthe
laboratory temperature 6960 1267 J.m2. Results of the
measurements showed the trend in the decrease of the
shear impact strength when changing the adherends,
however the statistical indicators are not arguable. Fig. 6
shows the results of shear impact strength at the
temperatures22,60and100C.AdhesivesLN7256,L1200
andKLPshowedincreasingtrendwiththetemperatureof
theapplication.
Fig.3 Crashing area of ceramic plate after impact 25 J of

Charpyhammer(wasnotadhesivebonded).
Fig.6Shearimpactstrengthofadhesivebonds.
The failure area of above mentioned adhesives visible in
fig.7,8,9wasofthecohesivetype.
Fig.4 Crashing area of ceramic plate after impact 25 J of

Charpy hammer (adhesive bonded, place of crashed is
marked).
Fig.7FailureareaofcohesivetypeadhesiveLN7256
The research showed potential significant application of
the rubber filler in the twocomponent epoxy adhesive.
Against standard offered adhesive the composite system
showedtheincreaseoftheshearimpactstrengthupto80
%.Whentestingthecompositesystembasedonthetwo
component epoxy adhesive and the matted rubber it is
essential to reach the highest possible rubber
representation.
Fig.5 Ceramic plate failure and its delamination in

adhesivelayer.
128
Fig.8FailureareaofcohesivetypeadhesiveL1200
Fig.9FailureareaofcohesivetypeadhesiveKLP
Fig.10FailureareaofcohesivetypeadhesiveNMET
Fig.11FailureareaofcohesivetypeadhesiveNtmel
Fig.12FailureareaofcohesivetypeadhesiveUHU300
Fig.13FailureareaofcohesivetypeadhesiveUHUM
The results showed that the final impact strength can

decrease about 30% against saturated solution of
prepared composite mixture. The results of composite
systems based on the polymeric particle composite on
basisofgrindingtheretreadedtyresshowwidespectrum
ofsolutions.Secondarybenefitforpracticalapplication is
up to 20% savings of the adhesive consumption. The
second group are adhesivesNMET, Ntmel, UHU300 and
UHUM showing the increase of the impact strength of
adhesive bonds owing to the temperature until the
temperature 60C. The failure areas of these adhesives
werealsoofcohesivetype(fig.1013).
Thethirdgroupareadhesives3TON,MTBand NKwhich
showed the decrease of the impact strength of adhesive
bonds owing to increasing temperature. These adhesives
werealsocohesivefailure(fig.1416).
Fig.14Failureareaofcohesivetypeadhesive3TON
129
Fig.15FailureareaofcohesivetypeadhesiveMTB
Fig.16FailureareaofcohesivetypeadhesiveNK
T test results of dependence show that the impact

strengthoftheadhesiveLN7256(p=0.19),Ntmel(p=0.2),
KLP (p=0.21) is the same with the adhesive 3TON at the
laboratorytemperature.Thesameisvalidfortheadhesive
L1200 (p=0.94), UHUM (p=0.46) and NMET. At the
temperature60C,theadhesiveMTBhasthesameimpact
strength with the adhesive L1200 (p=0.6) and UHUM
Tab.1ANOVAtest
(p=0.4), the adhesive KLP has same strength with the

adhesive LN7256 (p=0.73) and Ntmel (p=0.12). At the
temperature 100C, the impact strength of adhesives
3TON and MTB (p=1) are the same, the adhesive NMET
with the adhesive UHUM (p=0.69), the adhesive UHU300
withtheadhesivesNtmel(p=0.12)andL1200(p=0.24).
2
Onedimensionaltestsofsignificance,effectsofforceandimpactstrengthofadhesivejointsJ.m
SS(thesumofsquareddeviations) degreesoffreedom MS(mean square)

F
Intercept
2,368363E+10
1
2,368363E+10
7422,874
adhesive
2,507088E+09
8
3,133860E+08
98,221
Temperature
3,633369E+08
2
1,816684E+08
56,938
Adhesive*temperature
8,688459E+08
16
5,430287E+07
17,019
Error
8,710415E+08
273
3,190628E+06
sufficiently firm, elastic and temperature resistant bond.

The experiments showed that the elasticity of
constructionaladhesivescouldbeincreasedbyaddingthe
filler in the form of the rubber. The laboratory
experiments confirmed that the ceramic material based
on Al2O3 is fragile. However, the laboratory experiments
proved the ability of the adhesive layer to be a damping
member in the system metal/ceramics. Reaching the
marginal state of the adhesive layer delamination the
ceramicplatewasbrokenconsequently.Theadvantageof
thissolutionistheecologicalaspectinminimizingthesoil
contaminationbytheelementsCr,VandWcomingfrom
thehardoverlaysorcementedcarbides.Costsforcreating
bond are lower against brazing. Costs per one bond of
sizes50x15mmareintheinterval0.30.5Euro(atthe
adhesivelayerthickness0.06mm).
Theanalysisshowsthesignificantdependenceamongthe
adhesive type, temperature and resulted shear impact
strength(Tab.1).Thecombinationoftheinfluencesofthe
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. So it is not possible to
prove the decrease of the impact strength value with
increasing temperature or contrary. On the contrary, the
impact strength increases till given temperature at some
adhesives and consequently the impact strength
decreases with higher temperature. From the practical
application point of view it is possible to recommend
developedadhesiveonthebasisofthepolymericparticle
composite with the rubber admixture. Increasing of its
impact strength can be presupposed when applying the
fillerintheformoftherubber.Itcanbethetopicofnext
testing.Owingtoitsviscousnaturethehandling,layingon
and stability in the bond during the hardening process
wouldbesignificantlyimproved.
ACKNOWLEDGEMENT
ThispaperhasbeendonewhensolvingTARTA01010192
(20112014,TAO/TA).
REFERENCES
CONCLUSION
[1] BAYHAN,Y.Reductionofwearviahardfacingofchisel
ploughshare. Tribology International. 2006, 39 (6):
570574.
[2] SNENISO1791.PlasticsDeterminationofCharpy
impactpropertiesPart1:Noninstrumentedimpact
test. Prague, 2010, Czech Standard Institution. (in
Czech)
[3] SN EN ISO 965. Adhesives Test method for shear
impact strength of adhesive bonds. Prague, 2001,
CzechStandardInstitution.(inCzech)
[4] HORVAT Z., FILIPOVI D., KOSTIC S., EMERT R.
Reduction of mouldboard plough share wear by a
combination technique of hardfacing. Tribology
International,2008,41(8):778782.
The effective solution applied in the agriculture are the

iron, noniron and nonmetal materials distinguished for
high wear resistance which do not contaminate the soil
duringthewearprocesscomingintobeingduringthesoil
processing. The disadvantage of these materials is low
abilitytoresistagainsttheimpactofvariousfirmparticles
contained in the soil. The second disadvantage is the
necessity to create firm bond and reliable bond. In the
papertherearestatedresultsoftheresearchfocusedon
untraditionalpossibilitiesofincreasingthewearresistance
ofthesoilprocessingtoolsbymeansoftheapplicationof
ceramicplatesonexposedplaceofthetool.Theadhesive
bondingtechnologysolvestheproblemwithcreation
130
p
<0.001
<0.002
<0.003
<0.004
[5] CHOTBORSKR.,HRABP.,MLLERM.,SAVKOVJ.,
JIRKA M. Abrasive wear of high chromium FeCrC
hardfacing alloys. Research of Agriculture
Engineering.2008,54(4):192198
[6] MEDVEDOVSKI, E. Wearresistant engineering
ceramics.Wear,2001.249:821828.
[7] MLLER, M., CHOTBORSK, R. Apparatus for
evaluation of shear impact strength of adhesive
bonds,CZ23582U1,2012
[8] NATSIS,A,GPAPADAKISaJPITSILIS.Theinfluenceof
soil type, soil water and share sharpness of a
mouldboard plough on energy consumption, rate of
work and tillage quality. Journal of Agricultural
EngineeringResearch.1999,42(2):171176.
[9] NATSIS, A., G. PETROPOULOS a C. PANDAZARAS.

Influence of local soil conditions on mouldboard
ploughshare abrasive wear. Tribology International.
2008,41(3):151157.
[10] OWSIAK, Z. Wear of symmetrical wedgeshaped
tillagetools.SoilandTillageResearch.1997,43(34):
295308.
[11] SARE I. R., CONSTANTINE A. G. Development of
methodologies for evaluation of wearresistant
materialsformineralindustry.Wear,1997,203204:
671678.
[12] SUCHNEK J., KUKLK V., ZDRAVECK E. Abrazivn
opoteben materilu (Abrasive wear of materials).
Prague,2007,CTU.
131

TheProceedings
Electro-Hydraulic System for the Simulation of Dynamic Behaviour

of Rocket Engine Flexible Nozzle Thrust Vector Control
DraganB.Nauparac1DraganH.Pri2MarkoMilo3
1
MScMechanicalEngineering,ProjectEngineer,PPTEngineering,Belgrade,Serbia,email:dnauparac@beotel.net
PhDMechanicalEngineering,AssistantProfessor,UniversityofKragujevac,FacultyofMechanicalEngineeringKraljevo,Serbia
2
3
ARTICLEINFO:
Abstract:
Electrohydraulicactuator
Flexiblenozzle
Loadsimulator
Servodistributor
This paper presents the reasoning behind experimental simulation of dynamic behaviour of rocket engine flexible
nozzle. Electro-hydraulic actuator system sets in motion and controls flexible nozzle. As a load to electro-hydraulic
actuator, flexible nozzle is characterized by severe non-linear nature that cannot be precisely modelled. Since,
mathematical model is essential in the design of electro-hydraulic actuator system, for the synthesis and analysis of
its control algorithm, actuators load cannot be a subject of un-modelled dynamics and unknown parameters.
Standard solution in design practice is identification of dynamic behaviour, i.e. development of linear or non-linear
mathematical model based on the real, measured responses of an actuator system. This paper elaborates on
justification for using adequate load simulator for testing electro-hydraulic actuator system, prior to the identification
of electro-hydraulic actuator system, as an inter-phase in the design of electro-hydraulic actuator system. In the
case of flexible nozzle, identification is relatively complex, since conditions identical to those during the flight cannot
be obtained on the ground, so simulation techniques become increasingly important. Crucial is that simulation
conditions, stricter than in reality, can be generated, thus compensating for the lack of real flying conditions for
testing. Using a simulator does not require construction of nozzle within a rocket engine chamber.
Citation:NauparacDB,PriDH,MiloM.Electrohydraulicsystemforthesimulationofdynamicbehaviourofrocketengineflexiblenozzlethrustvectorcontrol,2ndInternational
INTRODUCTION
constructions and sealing systems. This means that the
dominant friction is external and as a load, it has both
positiveandnegativerole.Positively,itincreasesthelevel
of actuator systems damp, while negatively, it can be a
cause of instability. External frictions nature is also non
linear. In flexible nozzle, dominant is viscous friction that
can significantly change over the time, which gives an
actuator system a nonstationary character. Previously
stated confirms that when a direct mathematical
modellingcannotresultinaprecisemodel,differenttype
ofanalysisshouldbeapplied.Oneofthetechnologiesfor
obtaining missing information on actuator system, i.e. its
load, is the identification. Identification is performed on
alreadybuiltmodelofcompletelyrealisticload,complete
nozzle construction and rocket engine chamber. (HILS
HardwareinLoopSimulation)Beforetheidentificationof
dynamicparameters,asaninterphaseinelectrohydraulic
actuator systems design, suggestion is to design a load
simulator that can realistically simulate intensity of
actuatorsload,bygeneratingadequateforceintime.This
means that load intensity can be realistically simulated,
whilecharacterofchangeinintensitycannotbeprecisely
determined,becauseitdependsonrealelasticforcesand
friction forces that change with a temperature, which
changes in time. Still, much unfavourable character of
change in load, from the envisioned, can be defined. By
doingso,advantageoverrealload(realflexiblenozzle)is
created, and load simulation can be performed with
certainreserveoncharacterofchangeinload.Generating
greater load intensity than expected in reality can
compensate for not knowing the character of change in
load.Previouslydescribedtestingtechnologyforactuator
systemispresented,inthispaper,ontheexampleofthe
design of electrohydraulic actuator for rocket engine
flexiblenozzlesthrustvectorcontrol.Flexiblenozzleisan
extremely complex load to be mathematically modelled,
primarilyduetoitsnonlinearnature.
Electrohydraulic actuator systems are characterized by

severenonlinearnature.Nonlinearitycanoriginatefrom
theveryconfigurationofanelectrohydraulicsystemand
load. In practice, a significant part of electrohydraulic
actuator systems nonlinear nature can be compensated
by making a good choice of components of electro
hydraulic system. Among these components, in the first
place, come: servodistributor with zero lap, work of
actuator system with no saturation on control and no
saturation on hydraulic cylinder stroke and selection of
cylinderwithtwosidedpistonrod.Bydoingso,onlynon
linearityofflowcharacteristic,asafunctionofrealdropin
pressure in actuator, remains. [1] It is more difficult to
solve a problem of nonlinear nature of real actuator
systems load. In practice, significant simplifications are
used, that can be verified on the example of flexible
nozzle,suchas:loadmassisperceivedtobeconcentrated,
loosely tied to an end of a piston rod. In reality, mass is
almostneverlooselytiedtothepistonrod.Usually,there
isatleastoneotherlinktotheenvironment.Thisimposes
a question of determining, so called, reduced or
equivalentmass,aswellastakingintocountelasticforces
between concentrated masses. These forces primarily
influence own frequency of closed electrohydraulic
actuator system, frequency that is usually calculated,
solely based on concentrated mass. Sometimes, in this
problem, a load is presented with a several concentrated
masses with appropriate elastic joints between them [6].
However, actuators own frequency is important initial
input in the control system synthesis process. Based on
this information, actuator system bandwidth can be
immediately evaluated, as well as the applicability of
simplePregulator.Ageneralruleisthatforthehalfofa
bandwidth,Pregulatorshouldachievesatisfactoryresults
(sinusoid change of actuators target position value). This
isadequatecriterionfortestinganactuatorsystemwitha
load simulator. Besides, external friction for almost all
loads is significantly bigger from the friction in hydraulic
cylinder, where it is reduced to minimum by using new
132
Electro-Hydraulic System for the Simulation of Dynamic Behaviour of Rocket Engine Flexible Nozzle Thrust Vector Control
FLEXIBLENOZZLEACTUATORSLOAD
Flexible nozzle construction is shown in Fig. 1. In
mechanicalsense,thisisrelativelysimple,meaningalsoa
cheap,construction,butatthesametime,averycomplex
one for mathematical modelling as a hydraulic cylinder
load.Flexiblejointischaracterizedbyhighhysteresisthat
changes in time depending on temperature. Group of
authors, in paper [2], suggested the initial modelling of
flexible nozzles dynamic behaviour by using certain
functionsinMatLabtogetherwithexperimentaldatafrom
stressdeformation diagram. Fig. 2 shows flexible joint
characteristic character forceangle after modelling. In
general,thistypeofaloadcanbedefinedasanonideal
spring. Mathematical description of this spring is not
simple. Since maximal forces can be determined from
experimentaldataforflexiblejoint,spectrumofforcescan
becreatedtoloadelectrohydraulicactuator.Fig.3shows
functional scheme of electrohydraulic simulator of
flexiblenozzlesdynamicbehaviour.
THE IMPORTANCE
CONSTRUCTION
ax
OF
FORCE
SIMULATOR
Construction of a force simulator is very important when

actuator load is flexible nozzle type. First, the very
identificationprocesshascoupleofshortcomings.Ifanon
linear identification is applied, it is performed based on
oneinputsignal,whichisabiglimitation,whenexpecting
significant change in some of the load parameters.
Second, if a linear identification is applied, several
different transfer functions will be obtained for different
amplitudesofinputsignal,i.e.nominalvaluesofvariables
aroundwhichthelinearizationwasperformed.Third,itis
irrational to conduct large number of real experiments
with flexible nozzle, because it requires a running rocket
engine. In this case, a hydraulic simulator enables force
simulation up to the sought intensity, but simulation of
load force change in character, as well, in much wider
scopethenitrealisticallyhappensonaverage,onflexible
nozzle.Itissaidaveragesincenatureoftheobjectissuch
thatasignificantrepetitivenesscannotbeachieved.When
thatisthecase,forcesimulatorenableshaving,relatively
easy, covered entire scope of assumed changes in load
and broadening the scope in order to provide with
guarantee for actuator robustness and control algorithm.
When control synthesis results are confirmed in such
situations,certaininfluencesofloadstructure,suchasreal
buildin, i.e. joint stiffness and influence of real inertial
load(reducedmass)arebeingverifiedontheverymodel.
It should be pointed out that hydraulic simulator enables
loadingactuatorwithforceoscillationsthatoriginatefrom
pulsing operations of rocket engine, and are being
transferredfromthechambertoflexiblejointandnozzle.
L ac
Fm
DB Nauparac, et al.
discusses hydraulic force simulator and force simulator

with pendulum for flexible nozzles electrohydraulic
actuator.
Fig.1Schematicviewofflexiblenozzleconstruction.
MATHEMATICAL MODEL OF AN ACTUATOR AND

SYSTEM FOR SIMULATION OF HYDRAULIC
CYLINDERLOAD
For the simulation validation of force simulator
construction, i.e. flexible nozzles dynamic behaviour, a
mathematical model, defined through following
equations, was proposed and block diagram in Simulink
presented in Fig. 6. In the functional scheme it can be
observedthatthebasicideawastohaveservodistributor
and actuator distributor, control the cylinder that
simulatesload.Separatepumpsareusedtopowerservo
distributor. Basic actuator system is being observed as
positional,butthechangeinforceisbeingobservedwhen
thepistonrodspeedchangesinloadcylinder.
O63/36x200
O50/28x200
Fig.2Staticloadcharacteristicaftermodeling.
On electrohydraulic actuator, load is simulated via
cylinderthatisconnectedtoactuatorcylinder.[7]Having
this setup, there is a possibility to load an actuator
cylinder with adequate forces (variable load) at given
speed of actuator system. Fig. 5 shows position of force
transducer that enables measuring real losses, primarily
due to the friction in cylinders when simulating a force.
Alternativetothisconceptwouldbealoadsimulatorwith
pendulum. Its advantage is that certain elastic joints can
bedefinedinstructure,usingdatafrom[2],andinserted
in the functions from Fig. 13. In one load simulation
configuration,isnotpossibletoprovidebothawiderange
of options for change in load intensity and adequate
simulation of elastic forces. Hence, this paper separately
EM
Fig.3Functionalschemeofelectrohydraulicsimulator
133
D.B. Nauparac et al.
Previous equations (1) (4) can be simplified, under the

assumptionthatinternalleaksincylinder(Ql1 iQl2)donot
exist,aswellasthattheconstantvolumeinsideacylinder
is significantly bigger than variable VTc1(2)0>>AT.x, so that
for mathematical simulation following equations are
obtainedintheformof:
p1
p2
(Q1 AT x )
VTc10
VTc 02
(5)
(AT x Q2 )
Equations (5) are implemented in block diagram for

simulationinFig.6.
By modelling load cylinder the same way as the actuator
cylinderwasmodelled,followingequationinfinalformis
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,basedonwhichacompleteblockdiagraminFig.
6isdevelopedis:
(7)
m eq x p1 AT p L 2 AL 2 p 2 AT p L1 AL1 FF sign ( x )
Inglobalapproach,knowingthatwhenanactuatorsystem
actsontheload,thefastestisthechangeinforces,then
changeinspeedandposition.Inthatcaseloadcylinderis
expected to have a greater bandwidth for the force than
the actuator cylinder, in order to enable generation of
forcesthatcorrespondtotherealload.Thisfactneedsto
be taken into consideration when choosing the load
cylinderdimensionsandservodistributors,sincethoseare
the most important factors for provision of the greatest
possiblebandwidthforforce.
Fig.4Loadsimulatorwithpendulum,Simulinkmodel
x
AT
AL
p L2
p1
pL1
LOAD
CELL
p2
m TC
m LC
Fig.5Buildinforcetransducer
Mathematicalmodelofaloadsimulatorforanactuatoris
based on classical linear description [5], [6] so the
followingisobtained:
..
( 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
Basedon(1)and(2)equationforforceisobtained:
(2)
FFT ( FL p L AL ) p1 AT p L AL ( mTc m Lc )
(3)
Fig.6 Block diagram of simulators mathematical model

withloaddefinedviacylinder
FFT p1 AT ( mTc m Lc ) FL
Actuator,equationforflow:
MATHEMATICAL MODEL OF AN ACTUATOR AND

SYSTEM FOR SIMULATION OF MECHANICAL
PENDULUMLOAD
dVTc1 VTc1 dp1
,V V AT x
dt Tc1 Tc10
dt
dV
V dp
Q2 Ql 2 Tc 2 Tc 2 2 ,VTc 2 VTc 20 AT x
dt
dt
Fig.4showstheconstructingideaofforcesimulatorwith
pendulum. Nozzle is represented by a pendulum
supported by elastic support structure a flexible joint
betweennozzleandrocketenginechamber.Inthismodel,
inertialloadcomponentcanbeeasilychanged.Thereare
not many concentrated masses, but pendulum and
Q1 Ql1
(4)
134
DB Nauparac, et al.
movable actuator mass (piston and piston rod) are

modelled as a single mass. Mechanical part of a load on
actuatorismodelled,firstthroughbondgraph(Fig.8),see
Annex and then the model in introduced in Simulink
model.
Fig.11 Response in the case of saturation of spring static

characteristic
Fig.7Testcylindersspeedchangeforoscillatingchangein
pressure
Fig.12Changeinresponsewhenviscousdampinspringis
reduced
Provide with constant common speed of piston rods,
(closed loop control) of load cylinder and actuator, of +/
20% of predetermined speed, which is one of the basic
requirementsinloadsimulationbyintensity.Themodelof
hydraulic simulator has very high nonlinear nature and
fineadjustingisnecessary.
Changeinpressureinaloadcylindercanbegiveninmany
forms.Fig.9,10,11and12showthesimulationresultsof
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. 9); when
there is an insensitivity zone (Fig. 10); when there is a
saturation in static characteristic (Fig. 11) and with the
changeinviscousfrictioncomponent(Fig.12).(Allisopen
loopcontrolfordifferentdesiredangleofnozzle.)
Fig.8Bondgraphofpendulumasmechanicalsimulatorof
load
CONCLUSION
This paper presents the justification of steps in
experimental load simulation for an actuator system,
through adequate argumentation and results from
mathematicalsimulations.Itisclearthatonlyonetypeof
load simulator a hydraulic cylinder, could not simulate
theentireloaddynamics,butonlyachangeinintensityof
force(Fig.6andFig7).Buttogetherwithpendulumtype
load simulator, dynamic behaviour of an actuator with a
flexiblenozzleloadtype,canbecompletelymodelledwith
allelementsofnonidealspringtypeload(Fig.912)
Fig.9Changeinreferentangle(Fir)andangle(Fi)whenan
idealspringisobserved
Acknowledgement
35044).
REFERENCES
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[2]
Fig.10 Response in the case of the insensitivity zone

existence
[3]
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Adequate Control Algorithm for Electrohydraulic
Actuator Applied on Rocket Engine Flexible Nozzle
Thrust Vector Control, 14 th ITI, Symposium,
Dresden,October2011.
D.Nauparac, D.Pri, M.Milo, Design Criterion to
select adequate control algorithm for electro
hydraulic actuator applied to rocket engine flexible
nozzlethrustvectorcontrolunderspecificload,FME
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[4]
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[6]
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IdentificationandControl,Springer
D.E.Schinstock,D.A.Scott,T.A.Haskew,Modelingand
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D.Henriksen, Design and Construction of a Facility

for Testing Friction in Hydraulic Cylinders (student
report),AlborgUniversity,Aalborg,September2009.
Pri D., Nedi N., Dubonji Lj., Djordjevi V., "Bond
Graph Modeling In Simscape", International Journal
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2,Volume6,2012,pp.239247
Simscape3,LanguageGuide,TheMathWorks,2009

TheProceedings
Laser Feedback System for Accurate Sub-Micrometer Positioning

TomaszPodornyGrzegorzBudzy1JanuszRzepka1
1
InstituteofTelecommunicationandAcoustics,WroclawUniversityofTechnology,Janiszewskiego7/9,50370Wroclaw,tomasz.podzorny@pwr.wroc.pl
ARTICLEINFO:
Abstract:
Metrolgy
Interferometry
Micrometryrangemeasurements
Nanometryrangemeasurements
Positioning
This paper presents an approach to a laser interferometry based feedback systems for accurate sub-micrometer
range positioning. Abbe error minimization due to direct measurement of an object and high dynamic range are the
main advantages of laser interferometery devices. Error cancelation and linearization techniques allow to obtain
decent accuracy for various applications. Displacement measurements are performed by high linearity laser
interferometer with resolution of 100pm. The maximal velocity of tracked translation is up to 7m/s. Analogue sine
and cosine or digital quadrature signals are generated by the feedback system. Those signals are automatically
compensated by digital signal processing. There is presented error budget for a heterodyne setup of the laser
interferometer and accuracy is estimated. Presented work introduces three main groups of error sources which are
significant contributors to overall accuracy of the system. There are discussed errors caused by frequency stability
of laser source, by the quality of optical path alignment and by environment conditions. Every group is analyzed and
most significant errors are indicated. According to this analysis software and hardware methods to minimize error
sources are proposed. Achieved accuracy for stage positioning is below 1m per 10m for non-vacuum applications.
Citation: PodornyT.,etal. LaserFeedbackSystemforAccurateSubMicrometerPositioning,2ndInternationalConferenceManufacturingEngineering&Management2012,(2012),p.

137140,ISBN9788055312163
INTRODUCTION
Introducedmethodsallowtoobtainaccuracyintherange
of few micrometers at long distances for machine
industry where high dynamic range is expected. It is also
possible to provide decent positioning parameters for
nanotechnologyapplicationsthatneedtheresolutionand
accuracyintherangeoffewnanometers.
Applications requiring fast and accurate positioning in a

submicrometer range are becoming more and more
popular. This is mainly caused by fast development of
machine and nanotechnology industries. Laser
interferometrysystemscouldoffersuperioraccuracyand
very high dynamic range in displacement measurements.
Due to lowered prices, nowadays they are becoming an
attractive alternative for linear scales in many industrial
applications.Itisevenpossibletomeasuredisplacements
with a resolution of few picometers using interferometry
devices. Achieving the accuracy in this range is a very
demandingtask,though.
Therearemanyerrorsourcesaffectingtheaccuracyinthe
displacement measurement. They can be grouped into:
environmental errors, geometry errors and instrumental
errors. In general the environmental error group is the
main contributor to the overall error, especially in a long
distance and long term measurements. The geometry
errors have similar properties but they are lower than
environmental errors. Despite the fact that the
instrumentalerrorsgroupisthelowestcontributortothe
overall error, in the region of few nanometeres is has to
betakenintoaccount.
Error compensation is avery important task in the
industry applications where it is impossible to maintain
stable conditions during measurements. According to
leading manufacturers of such devices, like Lasertex or
Renishaw, it is possible to measure displacements with
accuracy in the range from 0,5 ppm to 1,5 ppm at long
distances. In the nanometry range nonlinearities are
subject of interest of many research groups. It was
presented by Joo et al [1] that there is a possibility to
reduceerroreventothevalueoffewpicometers,butitis
hardtoimplementthosetechniquesintheindustry.
Fast signal processors and efficient algorithms enable
accuratemeasurementsinatypicalindustryenvironment.
In this work there is presented an approach to use
innovativeerrorcompensationtechniquescombinedwith
high performance digital processing devices to provide
accurate feedback signal for positioning applications.
ERRORBUDGETINLASERINTERFEROMETRY
SYSTEM
The relation between uncompensated errors caused by
environment, geometry and instrument is presented in
thefigure1.Errorswerecalculatedfor10mdisplacement
and deadpath set to zero. The environmental error was
calculated according to Edlns equation [2] with an
assumption that temperature, pressure and humidity
change respectively by 1 C, 1 hPa and 10%. For
geometrical error there were taken into account cosine,
Abbe[3]anduniformityerrorsofretroreflectorormirror.
Thecosineerrorwasestimatedusinganassumptionthat
measurement beam changes position according to the
referencebeamby5mmonthewholemeasureddistance.
TheAbbeerrorwascalculatedwith10radand0,1mmof
Abbeangleandoffsetrespectivelybetweenatargetanda
retroreflector. The uniformity of the target retroreflector
errorwascalculatedforopticswithqualityof/10.Laser
stability, electronics error and nonlinearities are the
largestcontributorstotheinstrumentalerrorgroup.
Instrument
Environment
10
12
14
Fig.1 Relation between the main error groups for 10m

displacement.
Error [m ]
A heliumneon laser tube with digitally controlled

stabilizationloopandferroelectriccrystalwasusedforthe
137
Geometry
T. Podorny et al.
experiments. The frequency stability for short and

medium averaging times was in the range of 0.001 ppm
[4]. Electronics errors are mainly caused by noises and
nonlinearities from electronics circuits and algorithms.
Heterodyne configuration of the laser interferometer
eliminateseffectslikeoffsetsandtheirdrift,1/fnoiseand
sensitivity to laser power variation. The electronics error
value was estimated to 0.2 nm. 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.
Theywereestimatedtobeintherangeof15nm.
According to the presented results instrumental error is
not applicable for long range measurements. However,
the instrumental error is the most important, because it
compensation has to be performed internally in the
measurement device. It is the lowest contributor to the
overallerrorbutothererrorsourcescanbeeliminatedby
proper alignment of the measurement path and
maintaining stable environmental conditions. Error
sourcescausedbytheenvironmentandgeometrycanbe
also neglected in the short term and short distance
measurements. The instrumental error is a concern
especiallyindynamicmeasurements.Inthefigure2there
is presented relation between error groups for 0,01m
displacement. All the assumptions made for figure 1 are
valid except cosine and target uniformity errors. The
cosine error was calculated using an assumption that
measurement beam changes position according to the
reference beam by 0,02mm on the whole measured
distance. The target uniformity error was also reduced,
because the laser beam is reflected almost in the same
pointoftheopticalcomponent.
Instrument
0,005
0,01
Geometry
0,015
analogue and digital signal generation. In the figure 3

there is shown the block schematic of presented
technique.
ERRORSCOMPENSATIONTECHNIQUES
The instrumental error group consists of laser frequency
stability error, errors caused by electronic circuits and
algorithms, frequency and polarization mixing errors. The
laserfrequencystabilityerrorisintherangeof0,001ppm
and can be neglected for displacements up to 10m. The
electronicserrorintheoverallinstrumentalerrorisinthe
range of 0,2nm and its value is independent on the
displacement value. Main contributors to that error are
nonlinearities and noise level of analogue and digital
algorithms blocks. The noise level was in the range of
0,1nm for the presented equipment. Signal processing
algorithms were simulated and it revealed that the
nonlinearities were in the range of 0,2nm. The most
significantfactorsthatincreasestheinstrumentalerrorin
the heterodyne configuration are frequency and
polarization mixing effects. Error caused by nonlinearities
has cyclic characteristic. It is related to the quality and
alignment of polarizing optical components, such as
polarizingbeamsplitters,halfandquarterwaveplatesand
the laser source. It can be expected that error resulting
fromnonlinearitiesachieveavalueupto20nm[6].There
are two main approaches to eliminate cyclic error in the
heterodyne configuration. First technique is based on an
optical setup which directly compensates parasite effects
due to modification of the classic heterodyne
configuration.ExperimentalresultspresentedbyJooetal
[1]revealedthatcyclicerrorwascompensatedtothelevel
of 20pm. Presented method is very effective but it
requires a more complicated optical setup. The modified
setup is very difficult to use in industry conditions. More
feasibleapproachisbasedondigitalsignalprocessingand
itisusedforboth,heterodyneandhomodynesetups[6,7,
8]. Those techniques implement circle or ellipse fitting
algorithms.Itispossibletocompensateofcyclicerrorina
real time without modification of the optical setup.
Approachpresentedinthispaperisbasedoncirclefitting
technique introduced in the previous work [6]. According
to the findings included there, quadrature measurement
signalcanbeexpressedbytwoequations:
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
whereAandBareamplitudesoforthogonallyandparallel
polarized beams respectively. Amplitudes of parasite
orthogonally and parallel polarized beams are indicated
respectively by and . The parasite beams results from
frequency mixing and their value is determined using
circle fitting algorithm. Obtained values are used to drive
cyclic error compensation unit implemented in the
hardware. This unit is presented in the figure 4 and is
multiplied for ISA and ISB signal paths. Offsets are
corrected using offset amplifier (OFF) through digital to
analog converter (DAC) and amplitudes by variable gain
amplifier (VGA). The environmental and geometrical
errorsstarttodominateovertheinstrumentalerrorinthe
overall accuracy budget in displacements exceeding
0,01m. Minimization of those errors in general relies in a
responsibility of the user of the laser interferometry
measurement system. Presented work introduces
methodsthathelptoeliminatethoseerrorsaslowasitis
possible in present measurement conditions. The
Environment
0,02
0,025
0,03
0,035
Fig.2 Relation between the main error groups for 0,01m

displacement.
Error [m ]
Fig.3Blockdiagramofthepresentedfeedbacksystem.
There are introduced techniques for minimization of all
the above mentioned error sources for nonvacuum
applications. The presented heterodyne laser
interferometer based feedback system provides
compensated analogue sine and cosine or digital
quadrature signals with configurable resolution.
Introduced method is based on the digital signal
processing. Errors are automatically compensated in the
real time using software and hardware blocks. Motion
controller unit is updated with compensated
measurement data at 100kHz rate. The controller unit is
built using FPGA logic to provide fast and accurate
138
T. Podorny et al.
geometrical error consists of the Abbe, cosine and target

uniformity errors. The Abbe error is related to the
alignmentanditisconstantovertheentiremeasurement
length.
circuit and 12bit analog to digital converter.

Measurements were also obtained using microcontroller
with stored multipoint calibration table and averaging.
Humidity according to Edlns equation has the lowest
impact on the wavelength change, but to decrease error
bellow 1nm, it has to be measured with 1% accuracy.
Humidity measurement was based on digital integrated
sensorwithappliedexternalaveraging.Datafromexternal
environmental sensors is collected during the
measurement and the result is compensated in a real
time. Reduced environmental error caused by the air
refractionindexchangewasintherangeof0,08ppm.
MEASUREMENTANDSIMULATIONRESULTS
Presented techniques were adopted to the heterodyne
configuration of a laser interferometer system. The
measurement system uses 12bit phase interpolation
algorithmimplementedinthedigitalprocessingunit.Data
from analog to digital converter is also feed to the
linearizationalgorithmsandcalculatedresultsareusedto
improve signal quality. The interpolation results in 0,1nm
resolution.Thesamplingrateofthesystemis100kHzand
itisabletotrackthedisplacementupto7m/stranslation
velocity. The velocity limit and the resolution are
correlated.Itispossibletoincreasethevelocitylimitwith
decrease of the resolution and vice versa. Interpolated
dataiscorrectedusingenvironmentaldataandfeedtothe
motion controller unit. It generates various standards of
signal for positioning applications. Measurement results
were collected over USB link on the personal computer
andalsotheconfigurationwasperformedinthisway.
In the figures 5 and 6 there are presented accuracy
improvement by nonlinearity correction in instrumental
errorgroup.Inthefigure5thereispresentederrorcaused
bynonlinearitiesoflaserinterferometerwithnonlinearity
correction block deactivated. In the figure 6 there is
presented error with nonlinearities compensated by
introduced technique. According to the presented static
measurements compensated nonlinearity error is lower
than1nm.
Fig.4Blockdiagramofthehardwarecircuitforcyclicerror
compensation.
Direct measurement of the object in the interferometry
measurements and proper alignment of the
retetroreflector to the measured axis allow its
minimization. The main contributors to the geometrical
error in the interferometry measurements are the cosine
error and the target uniformity error. The cosine error
appears when measurement beam changes its position
according to the reference beam orthogonally to the
measurement axis. Also the target uniformity error
appears in the same condition, because of target mirror
flatness uniformity and reflection point change. It is
possible to minimize that error using mirrors surface
mapping or reducing orthogonal movements of the stage
to the measurement axis by proper alignment of the
opticalpath.It isalsopossibletoreducethecosineerror
by using second approach. The only problem with
reducingthosetwoerrorsisrelatedtotheaccuracyofthe
alignment. It is not possible to notice small misalignment
on a short axis. The orthogonal position change of the
targetby0,5mmover0,01mmeasurementlengthresults
in 3m error. In presented work there was used position
sensitive device (PSD) and conditioning electrical circuit
for orthogonally polarized reference and measurement
beams. It was possible to detect position change with
accuracy better than 5m. Alignment with such accuracy
resulted in reduction of the cosine error below 1nm for
short displacements. In that case also target uniformity
error was significantly reduced. The alignment can be
monitoredintherealtimeoverUSBinterface.
Nonvacuumapplicationsrequirealsoenvironmentalerror
reduction. It is caused by lasers wavelength dependence
on the air refraction coefficient that is related to
environmental conditions (temperature, air pressure,
humidity,CO2content)andtemperatureexpandabilityof
components in measurement path. In this work only air
refraction index changes are taken into account, but it is
feasibletouseadditionalsensorstomeasuretemperature
of the components in the measurement path and
compensatetheirlengthchangeinapresenttemperature.
Wavelength of the laser source was compensated using
theEdlnsequationanddatafromtemperature,pressure
and humidity sensors. Temperature measurement were
performedusing18bitanalogtodigitalconverter,precise
lowdriftcurrentsourceforproducingareferencevoltage
over precise low ppm resistor and voltage across PT1000
sensor. Temperature measurements were performed by
microcontroller using multiple point calibration table and
averaging. Achieved accuracy was in the range of 0,05C.
Expected 0,1hPa accuracy pressure measurement was
obtained using integrated silicon pressure sensor with
temperature compensation, precise signal conditioning
16
14
Error [1 nm]
12
8
6
4
2
0
-2
11
13
15
17
19
21
23
25
27
29
31
Distance [10 nm]
Fig.5 Laser interferometer nonlinearities measured

withoutsignalcorrection.
0,8
0,6
Error [1 nm]
0,4
0,2
0
-0,2
11
13
15
17
19
21
23
25
27
29
31
-0,4
-0,6
-0,8
Distance [10 nm]
Fig.6 Laser interferometer nonlinearities measured

withoutsignalcorrection.
139
10
T. Podorny et al.

Instrument
0,1
0,2
0,3
Geometry
0,4
0,5
displacements up to 10m in a nonvacuum applications.

According to the presented findings errors caused by
environmentandgeometrywerethebiggestcontributors
to the overall error. Further error minimization is still
possiblebyusingbetterenvironmentalsensorsandmore
accuratebeampositiondetectionunit.
Environment
0,6
0,7
0,8
0,9
Error [m ]
Fig.7 Relation between the main error groups for 10m

displacement.
Instrument
Geometry
Acknowledgement
This work was cofinanced by European Union within
EuropeanSocialFund.
Environment
REFERENCES
0,0005
0,001
0,0015
0,002
0,0025
Error [m ]
Fig.8 Relation between the main error groups for 0,01m

displacement.
In the figure 7 there is presented relation between error
groups for 10m displacement. The environmental error
was reduced using introduced environmental block with
external sensors. The geometrical error was reduced by
proper alignment of the optical path with measurement
and reference beams monitor. Root square sum (RSS) of
those errors sources yielded overall error below 0,1m.
Therelationbetweenerrorgroupsfor0,01mdisplacement
is presented in the figure 8. There could be noticed
significantly reduction of instrumental error impact on
overallaccuracy.InthiscaseRSSerrorvaluewasreduced
below2nm.
CONCLUSIONS
Accuracy is significantly affected by environmental,
geometrical and instrumental error sources. Their
minimization is a very important and difficult task for
demanding positioning and measurement applications.
Effective and real time error reduction in the laser
interferometry systems is required for fast and accurate
feedbackapplications.Presentedresearchrevealedthatit
is possible to reduce the overall error below 0,1m for
140
[1] Joo K. N., Ellis J. D., Buice E. S., Spronck J. W.,

Munning Schmidt R. H. High resolution heterodyne
interferometer without detectable periodic
nonlinearity,OpticsExpress,Vol.18,Issue2,2010.
[2] Edln B. The Refractive Index of Air, Metrologia,
2(2):7180,1966.
[3] Abbe E. Messapparate fur physiker, Zeitschrift fur
instrumentenkunde,10:446448,1890.
[4] Budzyn G., Optokomutacyjna stabilizacja lasera
dwumodowego, PhD Thesis, Wrocaw University of
Technology,Wrocaw,2006
[5] WuC.M.,SuC.S.Nonlinearityinmeasurementsof
lengthbyopticalinterferometry,Meas.Sci.Technol.
7,1995.
[6] Budzy G., Podorny T., Rzepka J. A Universal Laser
Interferometer For High Linearity Measurements,
10th International Conference on Vibration
MeasurementsbyLaserandNonContactTechniques,
AIVELA2012.
[7] EomT.B.,ChoiT.Y.,LeeK.H.,ChoiH.S.,LeeS.K.A
simple method for the compensation of the
nonlinearity in the heterodyne interferometer,
Meas.Sci.Technol.13,2002.
[8] KeemT.,GondaS.,MisumiI.,HuangQ.,KurosawaT.
Simple, realtime method for removing the cyclic
error of a homodyne interferometer with a
quadraturedetectorsystem,AppliedOptics,Vol.44,
Issue17,2005.

TheProceedings
Electrical Discharge Machining of High Speed Steel Using Both

Liquid and Gas Dielectric
AnimeshPrakashGorvendraSingh
1
MechanicalEngineeringDepartment,IndianInstituteofTechnologyDelhi,Hauzkhas,NewDelhi110016,India
ARTICLEINFO:
Abstract:
EDM
Materialremovalrate
Toolwearrate
TaguchiDOE
EDM has been conventionally carried out in a liquid dielectric. 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. 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. The experiments are conducted
following Taguchi design of experiments. This study takes into account the influence of three design factors,
discharge current (DC), pulse-on time (Ton) and gap voltage (V). In this work, it is found out that the developed
hybrid machining process results in increase in MRR and reduction in TWR. Signal/Ratio analysis and Analysis of
variance calculations have been done to obtain the optimal value of design parameters. Empirical models for MRR
and TWR have been developed for the hybrid machining process.
Citation:Prakash,A.,Singh,G.: ElectricalDischargeMachiningofHighSpeedSteelUsingBothLiquidandGasDielectric,2ndInternationalConferenceManufacturingEngineering&
INTRODUCTION
Electrical discharge machining (EDM) is a non
conventional process of machining of electrically
conductive materials by using precisely controlled sparks
thatoccurbetweenanelectrodeandaworkpieceinthe
presenceofadielectricfluid.Theelectrodewhichmaybe
considered as a cutting tool is generally made of a
conducting material such as brass or copper. EDM has
greatadvantageinmachiningaworkpiecewithaspecial
shape or in machining hard material. Electrical discharge
machining (EDM) is generally carried out in a dielectric
liquid. The most commonly used dielectric fluid is
kerosene. The liquid dielectric has decisive role in the
performance of the process as it serves as the cooling
mediuminthedischargegapandflushesmachiningdebris
out of the working gap. Further, the efficiency and the
accuracy of performance have been found to improve
whenaforcedcirculationofdielectricfluidisprovided.
EDM in gas is a new machining method which was
proposed by Kunieda and Yoshida (1997). They observed
that the performance of EDM using gas (air and oxygen)
canbebetterthanthatwithaliquiddielectricundersome
especialsituations,i.e.,theuseofatubularelectrodewith
very thin wall (< 0.3mm), negative polarity of the
electrode,rotation/planetarymotionoftheelectrodeand
highspeedgasflow.Theirworkshowedthathighvelocity
gas flow through tool electrode reduces debris
reattachment after a spark, thus considered to be
effective in flushing. The debris reattachment is much
lower for a thin walled tube and this increases the MRR.
Material removal rate achieved with oxygen was higher
thanthatachievedwithair(55%)andEDMoil(21%)andit
is suggested that the heat generated by oxidation is
responsible for the increased MRR. The greatest
advantageofEDMingasistheverylowlevelofelectrode
wear (almost zero), which was reported to be
independentonthepulseduration.
Soni et al (1994) have observed an interesting
phenomenon related to providing rotary motion to the
tool electrode. The same was verified by Mohan et al
(2002) in their experiments. They have shown that MRR
increases with speed because of centrifugal force which
helpstoflushoutdebris,andconsequentlyimprovesMRR.
KuniedaandYoshida(1997)alsoobservedthatrotaryand
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. Having known that
conventionallytheuseofkeroseneasadielectricinEDM
processhasneverbeenquestionedandthatEDMcanbe
achieved in gas, we are intrigued to develop a hybrid
process of EDM employing both liquid (kerosene) and as
(compressedair)asdielectricswiththeobjectivetostudy
the effect of various machining parameters on MRR and
TWR,toobtainoptimaltoolwearrate(TWR)andmaterial
removal rate(MRR) and to evaluate the effect of
introductionofaironsurfaceintegrity.
EXPERIMENTALSETUP
All the experiments have been conducted on a Z
numerically controlled (NC) oil diesinking EDM Machine.
In this machine, the Z axis is servo controlled and can be
programmed to follow an NC code which is fed through
thecontrolpanel.Theservocontrolfeedbackisbasedon
the gap voltage between the tool and the work piece
electrodes. The gap distance cannot be independently
controlledonthismachine.TheXandYaxesaremanually
controlled. All three axes have an accuracy of 5m. The
power supply system produces a DC pulsed power in the
frequency range of 0.07 300 kHz. The pulse has been
idealizedbyconsideringthepulsedelaytimeasnegligibly
small.Thepulsecanbedefinedintermsofthegapvoltage
(Vg),dischargecurrent(I),pulseontime(Ton)andpulse
off time (Toff). An additional parameter, duty factor (d)
canberepresentedintermsofthepulseonandofftimes
as:
(1)
Work piece is taken as square block (size1.5 cm) of high

speed steel (HSS), which being a hard material poses
difficulty in machining through conventional methods.
Work piece is characterized by energydispersive Xray
spectroscopy(EDX)(Fig1).Toolelectrodeismadeupofa
141
A. Prahash, G. Singh
Electrical Discharge Machining of High Speed Steel Using Both Liquid and Gas Dielectric
Methodology
Based on the above mentioned design factors, a
comparative study of EDM is done with one case using
onlykeroseneasdielectricand theothercaseusingboth
kerosene and compressed air as dielectrics. Further,
experiments are conducted to study the effectof various
machining parameters on MRR and TWR. Signal / Noise
(S/N)ratioanalysisandAnalysisofVariance(ANOVA)tests
are then used for optimization of process parameters to
obtain optimal TWR and MRR and to identify the
significant parameters, respectively. Empirical models for
MRR and TWR will be developed by performing a design
experiment based on the central composite design of
experiments.Finally,surfacestudiesaredonetoevaluate
theeffectofintroductionofaironsurfaceintegrity.
copperpipewiththinwall(thickness0.5mm)whichhas
beenmadehollowtoallowthepassageofcompressedair.
Nozzle connection is done on the tool for the supply of
compressed air at 0.6 MPa. Further, rotary motion has
been provided to the tool electrode. Rotary motion has
been found to improve the material removal rate (MRR).
This behavior can be explained by the effect of spindle
rotation on the discharge phenomenon [1, 2]. To
incorporate the rotation of tool, it is held in a bearing
which itself fits inside a tool holder having a step hollow
passageof3.2cmdiameterstep.Apulleyispressfitonto
thetoolelectrodewhichisrotatedwiththehelpofabelt
connectingtothepulleyonamotorshaft.Awoodenstand
isusedforfixingthemotorandthestandisitselffitonto
the machine bed. A pressure regulator with range of 10
bar is used for sending compressed gas to the tool
electrode in a controlled manner. A flow control valve is
usedtoadjusttherateofgasflowaspertherequirement
of experiments. A motor is used for providing the rotary
motion to the tool required for experiments involving
introduction of air. Speed of the motor is 60 rpm with a
torqueof3Kgcm.Thepowerratingofthemotor is0.003
horsepower.ApartfromtheseTeflonpulleys,connecting
hoses and rubber V belts are used for completing the
experimentalsetup.Theratioofthediameterofpulleysis
5:1sothattherotarymotionisamplifiedbyafactorof5
making the tool to rotate at 300rpm. In the fully
assembled setup (Fig. 2), the compressed air coming
through the nozzle and the kerosene simultaneously are
used as dielectrics in the machining process. The
compressed air is delivered to the unit by a compressor
fitted in the laboratory. The hose is then connected to
pressureregulatorwhichisusedtoprovidecompressorair
tothesetupatdesiredpressure.Thepressurerangeofthe
pressure regulator is 10 bar. The air then flows through
theflowcontrolvalvewhichsetstheflowrateasperthe
requirements,beforefinallyreachingthetoolorifice.
Fig.1EDXofHSS
Tab.1Designparameters
Parameter
Discharge
CurrentA
Pulseon
time(s)
Gap
VoltageV
DESIGNOFEXPERIMENTS
ThepresentworkusesTaguchimethodforconductingthe
experiments and the analysis of the results hence
obtained.Inthissection,thedesignfactorsandresponse
variablesusedintheexperimentationwillbedescribed.
Designfactorsselected
In this work, discharge current (DC), pulse on time (Ton)
and gap voltage (V) are selected as design parameters
whicharethenvariedtofourlevels(Table1)resultingina
L16 orthogonal array of experiments. In the
experimentation, compressed air is kept at a constant
pressure of 0.6 MPa and the rotational speed of tool at
300rpm.
Responsevariablesselected
The response variables selected for this work are tool
wear rate (TWR), material removal rate (MRR), and
percentage tool wear rate (percentage TWR) which are
definedasfollows:
TWR
MRR
percentage TWR
(2)
(3)
Level2
Level3
Level4
100
200
300
400
40
50
60
70
Fig.2Experimentalsetup
RESUTLSANDANALYSIS
The MRR, TWR and percentage electrode wear are
calculated for both the cases: L 16 set of experiments
using kerosene only and using both kerosene and
compressedair(Table4.1).Acomparativeobservationof
MRRandTWRintheTable4.1showsthatthatuseofair
as dielectric results in increase in MRR, decrease in TWR
and also reduction in percentage electrode wear. Further
set of experiments were carried out keeping one of the
parameters among gap voltage, pulse on time, and
discharge current constant at the average level and
varyingtheremainingtwoparameterstothefourlevelsas
selected in design of experiments. The observations are
pictoriallydisplayedforMRR(Fig.4.2(a),(b),(c))andTWR
(Fig. 4.3(a), (b), (c))). 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.
(4)
142
Level1
Tab.2Designparameters
Experiment
Using kerosene only

TWR
MRR
Percentage
(g/min)
(g/min)
TWR
0.000200 0.008200 2.439024
Using kerosene and air

TWR
MRR
Percentage
(g/min)
(g/min)
TWR
0.000067 0.012467 0.534759
0.000267 0.010400
2.564103
0.000133 0.015333
0.000333 0.011867
2.808989
0.000400 0.008867
Increase in
MRR (%)
Reduction in
percentage
TWR (%)
52.032520
78.074866
0.869565
47.435897
66.086956
0.000200 0.018067
1.107011
52.247191
60.590405
4.511278
0.000267 0.020600
1.294498
56.060606
57.281553
0.000333 0.013333
2.500000
0.000133 0.015133
0.881057
26.111111
68.281938
0.000333 0.012867
2.590674
0.000133 0.015000
0.888889
25.698324
68.177777
0.000467 0.008333
5.600000
0.000333 0.022467
1.48368
53.181818
53.370072
0.000467 0.005133
9.090909
0.000333 0.022600
1.474926
48.684210
51.959544
0.000467 0.004933
9.459459
0.000200 0.018200
1.098901
20.264317
64.364207
10
0.000533 0.021200
2.515723
0.000267 0.020067
1.328904
20.400000
58.471760
11
0.000400 0.017267
2.316602
0.000200 0.018400
1.086957
38.000000
63.768115
12
0.000467 0.009933
4.697987
0.000267 0.020733
1.286174
41.363636
59.577400
13
0.000600 0.020467
2.931596
0.000333 0.023133
1.440922
23.928571
55.171309
14
0.000533 0.026600
2.005013
0.000333 0.023667
1.408451
39.215686
55.105633
15
0.000467 0.027933
1.670644
0.000267 0.021000
1.269841
36.956521
58.276643
16
0.000467 0.030533
1.528384
0.000267 0.021800
1.223242
45.333333
60.681520
S. No.
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
responsevariablesMRRandTWR.
Fig.3MRRvs.DischargeCurrent(Vg=55V)
Fig.4MRRvs.DischargeCurrent(Ton=250s)
143
Fig.5MRRvs.GapVoltage(DC=4.5A)
AnalysisforMRR
Since material removal rate is desired to be maximum,
equation corresponding to larger is better condition is
chosenandS/NratioforMRRiscalculatedusingequation
4.1
10
log10
1
N
1
y2i
(5)
Fig.6TWRvs.DischargeCurrent(Vg=55V)
Fig.7TWRvs.Dischargecurrent(Ton=250s)
Fig.8TWRvs.GapVoltage(DC=4.5A)
144
Fig.9S/NRatioandMeansplotforMRR
Main effects plot for S/N ratio and Means are drawn for
MRR (Fig.4.4) for kerosene only and, kerosene and air
both experiments. From the average S/N ratio for each
parameter at every level, optimal value of parameter is
identified (Table 4.2) as the level for which S/N ratio is
maximum.Forexample,fromTable4.2,theoptimalvalue
of current in case of MRR for both with and without air
cases is level 4 i.e. 6 A. It implies that using level 4 of
currentgivesmaximumMRRforboththecases.
voltage gap while effect of pulse on time is insignificant.

On employing air as well in the experimental design,
contributionofdischargecurrentlowerswhilevoltagegap
and pulse on time gain significance. It is probably due to
cooling and the flushing as well as oxidizing effect
providedbyair,thatcurrentbecomeslesssignificantand
pulseontimeandvoltagebecomesimportant.
Tab.3OptimalvalueofparametersforMRRandTWR
Parameter OptimalValueforMRR OptimalValueforTWR
Further, analysis of variance (ANOVA) is done to

determine the parameter which is most affecting the
result of experiments i.e. the parameter which
significantly affects the material removal rate. The values
of square sums obtained from ANOVA calculations are
usedtoplotpiechart(Fig4.5)whichgivesthepercentage
contribution of each parameter on the response variable
MRR. While using kerosene only as dielectric, discharge
current is the most important parameter, then comes
Current
Fig.10 Percentage contribution of design parameters to

MRRandTWR
145
With
With
With
With
kerosene kerosene kerosene kerosene
andairboth
only
andairboth
only
6A
6A
3A
3A
Pulseon
Time
400s
400s
100s
100s
Voltage
70V
70V
40V
40V
there are less than 0.0005 chances that such a large

Model FValue could occur due to noise. The final
Since tool wear rate is desired to be minimum, equation
regression equation for MRR in terms of the actual
correspondingtosmallerisbetterconditionischosenand
parametervaluesisshowninequation4.3:
S/NratioforTWRiscalculatedusingequation4.2
MRR=0.00137+0.00179DC+0.000014Ton+0.000165
10 log
(6)
Vg(7)
Figure12,13and14showtheresponsesurfacediagrams
Main effects plot for S/N ratio and Means are drawn for
ofMRRasafunctionofthedesignfactors.
TWR(Fig.4.6)forkeroseneonlyand,keroseneandairboth
ErrorinthemodeldevelopedforMRR
experiments. From the average S/N ratio for each
ThemodeldevelopedforMRRofhybridprocessisbound
parameter at every level, the optimal value ofparameter
is identified (Table 4.2) at the level for which S/N ratio is
to havesome errors. This error is calculated by using the
maximum..Forexample,fromTable4.2theoptimalvalue
equation4.4:UsingFtableforcalculatingthefvalues
of current in case of TWR for both with and without air
requiredintheexpression,theerrorpresentinthemodel
cases is level 1 i.e. 3 A. It implies that using level 1 of
isfoundtobe0.00191.
currentgiveslessTWRforboththecases.
Further,thevaluesofsquaresumsobtainedfromANOVA
RegressionanalysisforTWR
calculationsareusedtoplotpiechart(Fig4.5)whichgives
Similarly, based on a twofactor interaction model, the
the percentage contribution of each parameter on the
obtained model Fvalue of 44 implies that the model is
responsevariableSimilartothecaseofMRR,gapvoltage
and pulse on time gain significance upon use of air.
significant.ThefinalregressionequationforTWRinterms
Moreover,usageofairresultsinvoltagegapbecomingthe
oftheactualparametervaluesisshowninequation4.5:
mostsignificantparameterforTWR.
TWR=0.000287+0.000040DC+0.000000Ton+0.000005
Regressionanalysis
Vg(8)
On analysis of the experimental data obtained from the
Figure15,16and17showtheresponsesurfacediagrams
Taguchi design of experiments, models with significant
ofTWRasafunctionofthedesignfactors.
factor effects were obtained for MRR and TWR for the
ErrorinthemodeldevelopedforTWR
developed hybrid process of EDM using both liquid and
In a similar fashion to error for the model of MRR, the
compressedairasdielectric
errorcalculatedforthemodelofTWRusingequation4.4
AnalysisforTWR
comesouttobe0.000329.
Y=f/2,DFVe(9)
RegressionanalysisforMRR
Atwofactorinteractionmodelwasfoundtobethemost
suitable model based on the ANOVA sequential sum of
squares test. The obtained model Fvalue is 54.38 which
imply that the model is significant. According to analysis,
Fig.11S/NRatioandMeansplotforTWR
146
-4
x 10
3.5
0.024
-4
x 10
0.023
0.022
Electrode Wear Rate (g/min)
Material Removal Rate (g/min)
0.025
0.021
0.02
0.02
0.019
0.015
0.018
0.01
400
0.017
6
300
3
2.5
2
2
1
70
0.016
Discharge Current(Ampere)
1.5
300
0.015
4
100
Pulse On Time(microsec)
400
60
5
200
50
40
Gap Voltage(Volts)
200
100
Fig.12ResponsesurfaceofMRRvs.TonandDC
Fig.16ResponsesurfaceofTWRvs.VandDC
-4
x 10
0.024
-4
x 10
0.023
0.022
0.021
0.02
0.02
0.019
0.015
0.018
50
2
1
70
6
5
0.016
50
0.015
Gap Voltage(Volts)
0.021
0.02
0.02
0.018
0.019
0.016
0.018
0.014
70
0.017
400
60
0.016
300
50
200
40
100
0.015
Fig.14ResponsesurfaceofMRRvs.VandTon
-4
x 10
3.4
-4
x 10
3.2
3
2.8
2.6
2.4
2.2
2
1
400
1.8
6
300
5
200
1.6
REFERENCES
1.4
4
100
Inthiswork,ahybridmodelofEDMusingbothliquidand
gas dielectric has been successfully developed.
ExperimentationusingTaguchidesignofexperimentshas
led to the findings that use of compressed air leads to
increase in material removal rate and reduction in tool
wear rate. Using S/N ratio analysis, optimal values of
design parameters viz. discharge current, pulse on time
andgapvoltagehavebeenobtained.ANOVAtestsleadto
the conclusion that gap voltage becomes the most
significant parameter when both kerosene and air are
usedasdielectricascomparedtodischargecurrentbeing
themostsignificantwhenonlykeroseneisused.Further,
Empirical relations for MRR and TWR have been
developed for the hybrid process with a confidence level
ofmorethan95%.Thesuccessfulaccomplishmentofthis
work opens new avenues of further investigation on the
affectofuseofliquidcumgaseousdielectricsinelectrical
dischargemachining.Theconceptcanbeappliedtoknow
the response of different work and tool material to the
hybrid process. Other design parameters like the
rotationalspeedoftoolandgaspressurecanbevariedto
studytheeffectsonresponsevariables.Alsoimprovement
canbedoneinthefieldoftoolgeometryandequipment.
Moreover,experimentscanbeconductedbywarmingthe
kerosenetojustbelowitsflashingtemperature.
0.022
0.022
CONCLUSIONS
0.023
Gap Voltage(Volts)
Fig.17ResponsesurfaceofTWRvs.VandTon
Fig.13ResponsesurfaceofMRRvs.VandDC
0.024
1.5
4
40
4
40
Gap Voltage(Volts)
2.5
2
60
6
5
3
3
0.017
0.01
70
60
[1] B.Mohan,A.Rajadurai,K.G.Satyanarayana,Effectof
SiC and rotation of tool electrode on electric
discharge machining of AlSiC composite, Journal of
MaterialsProcessingTechnology124(3)(2002)297
304.
[2] J.S.Soni,G.Chakravarti,Machiningcharacteristicsof
titanium alloy with rotary electrodischarge
machining,Wear171(12)(1994)5158.
Fig.15ResponsesurfaceofTWRvs.TonandDC
147
3.5
0.025
CIRP AnnalsManufacturing Technology 53(1)

(2004)183186.
[7] V. Ramani, M. L. Cassidenti, InertGas Electrical
Discharge Machining, NASA Technical Brief Number
NPO15660,1985.
[8] Y. Zhanbo, J. Takahashi, N. Nakajima, S. Sano, K.
Karato, M. Kunieda, Feasibility of 3D surface
machining by dry EDM, International Journal of
ElectricalMachining10(2005)1520.
[3] M. Kunieda, M. Yoshida, N. Taniguchi, Electrical

discharge machining in gas, CIRP Annals
ManufacturingTechnology46(1997)143146.
[4] M. Kunieda, S. Furuoya, N. Taniguchi, Improvement
of EDM efficiency by supplying oxygen gas into gap,
CIRP
AnnalsManufacturing
Technology
40(1991)215218.
[5] M.Kunieda,Y.Miyoshi,T.Takaya,N.Nakajima,Y.Z.
Bo, M. Yoshida, High speed 3D milling by dry EDM,
CIRP AnnalsManufacturing Technology 52(2003)
147150.
[6] M. Kunieda, T. Takaya, S. Nakano, Improvement of
dry EDM characteristics using piezoelectric actuator,
148

TheProceedings
Textile Recovery from Srap Rubber Tires

AgtaRadvansk
TechnicalUniversityofKosice,FacultyofManufacturingTechnologieswiththeseatinPresov,SlovakRepublic,Email:agata.radvanska@tuke.sk
ARTICLEINFO:
Category:ShortCommunication
Abstract:
Tirederivedtextile
Scraptires
Fibers
Nonwoventextile
Geotextile
Shredded scrap tires alone or mixed with other materials can create the possibilities for their use in civil and
environmental engineering applications. Rubber-based material and steel have good properties and are able to be
recovered. The main problem is to find the area of textile recovery obtained from scrap tires. Although the reuse of
scrap tires and materials obtained from their manufacturing have become more common, questions regarding
environmental suitability still persist, particularly the potential impact on ground and surface waters and aquatic life
due to leaching. The paper provides a review of possibilities for tire-derived textile recovery and properties of the
obtained material.
Citation:RadvanskaA.TextileRecoveryfromSrapRubberTires,2ndInternationalConferenceManufacturingEngineering&Management2012,(2012),p.149150,ISBN97880553
12163
INTRODUCTION
Themaincomponentsusedintireassemblyareinnerliner
(halobutylrubber),bodyply(fabricandrubber),sidewall
(nonreinforced extruded profiles with additives
antioxidants and antiozonants), beads (bands of high
tensilestrength steel wire coated with special alloys of
bronze or brass), apex (filler), belt package (calendered
sheets consisting of a layer of rubber, a layer of closely
spaced steel cords, and a second layer of rubber), tread
(thick extruded profile that surrounds the tire carcass),
cushiongumandothercomponents(Figure1).[8].
Tab.1Analysisoftirederivedtextile
Chemicalanalysisoftirederivedtextile[mg.kg1]
Zn
22514
Cu
623
Mn
158
Co
63
Pb
35
Cr
18
As
6
Cd
1
Tl
0,4
Hg
0,03
Tire derived textile is not a pure textile material, it is a

mixtureofrubberandtextile,stillcontaining10to15%of
rubber material and small portion of steel thus the
characteristics are different from the synthetic textile
material(Figure2).[5]Chemicalanalysishasbeencarried
out by atomic absorption spectrometry and energy
dispersive Xray fluorescent spectrometry (EDXRF). Tire
derived textile is characterized by high zinc content
originating from zinc oxide added as activator in the
processofvulcanization.
Fig.1Theconstructionofatire[6]
The body ply consists of rubber layer, reinforcing fabric,
andasecondlayerofrubber.Theearliesttextileusedwas
cotton;latermaterialsincluderayon,nylon,polyester,and
Kevlar. Passenger tires typically have one or two body
plies. Body plies give the tire structure strength. Truck
tires, offroad tires, and aircraft tires have progressively
more plies. The fabric cords are highly flexible but
relativelyinelastic.[3]
Fig.2Textilefibersobtainedfromtireshreds
POSSIBILITIESFORREUSEOFTHETEXTILEFIBERS
The textile components of scrap tires can be sold to the
flocking industry. Items are shredded for fillers in car
insulation, roofing felts, loudspeaker cones, panel linings,
furniturepaddingetc.[8].Thepossibleuseoftirederived
textile is to form nonwoven fabrics, geotextiles or
insulation pads. Nonwovens from recycled fibers can be
potentially used asautomotivefabrics e.g. trunk liners or
insulation. Nonwoven fabrics are normally made from
continuous filaments or from fiber webs or batts
strengthened by bonding, using various techniques
including adhesive bonding, mechanical interlocking by
needling or fluid jet entanglement, thermal bonding, and
stitch bonding. The needlepunching, needlefelting, or
needlebondingmethodcanbeusedforfabricmaking.This
CHARACTERISTICSOFTIREDERIVETEXTILE
Manmade polymers have the advantage of not decaying
under biological and chemical processes, but being
petrochemicalbased products, they are made from
nonrenewable resources; and they also cause
environmentalpollutionintheirmanufactureanduse,and
have associated health risks. [5] The typical chemical
compositionoftextileobtainedfromscraptiresislistedin
Table1.
149
A. Radvansk
Textile Recovery from Scrap Rubber Tires
meanstousebarbneedlestoentangleafiberweborbatt
bymechanicalreorientationofsomeofthesefiberswithin
itsstructure.[2]Forthetirederivedtextilefibers,thebest
method to fabric manufacture seems to be a chemical
bonding system in which a chemical is used to reinforce
the web, typically a rubberbased, thermoreactive, or
thermoplasticbondingagentinsolution,powder,orfiber
forms. Fiber adhesives in the volume of 5 to 40% by
weightaremixedinwiththebasefibers.Thewebisthen
hotcalendered to cause the bond to form. The binder
fibers must have a lower melting point than the fibers in
the web and will be softened or melted by a hot
calenderingprocess,causingthebondtoform.
The tirederived textile could be the secondary raw
materialtoproductvariousforms,densities,andfinishes,
in the variable thickness. Thefelted products that can be
manufactured are as follows: car insulations, liquid
filtration felt circles, gaskets and seals, shoes insulation,
noiseandvibrationsdampeningmats,etc.Geotextilesare
permeable textile materials used for filtration, drainage,
separation, reinforcement, and stabilization purposes as
an integral part of civil engineering structures of earth,
rock, or other constructional materials. The predominant
form of fabric construction are spunbonded and
needlepunched nonwoven fabrics, primarily because of
cost and performance. These can be used for soil
stabilization or separation, asphalt overlay, liners,
reinforcements, drainage, erosion control, silt fences,
environmental protection fabrics. [2] Needlepunched
fabrics are used where it is required to prevent leakage
andprotectgroundwaterandsoil,asageotextilecushion
specificallywherethereisneedforpunctureprotectionon
topoftheliner,asblanketsindrainagesystemsinsidethe
landfill,asatarpaulinontheoutsideofthelandfill,andas
underneath riprap (gravellike material) for erosion
control. [1] The sound and shock absorbing materials are
formed from resinbonded webs transformed into flat
molded parts with selfadhesive surfaces or with a heavy
coating.Anotherconsistsofmoldedpartswithorwithout
textilelaminationandservesbothassoundinsulatorsand
as selfsupporting stylish components, for example,
insulationfittedunderthehood,intheroofsection,andin
trunk linings. Next group consists of hardpressed parts
used to line doors, backs of seats, and roofs. [4] Fabrics
from recycled fibers used for landscape applications
should be strong enough to withstand the most vigorous
stresses of application, should have an even, and
consistent distribution of fibers, and a small enough
opening size to keep weedy grasses from coming up
through the fabric. The fabric must be porous enough to

allow water and air to pass freely to the soil. The main
disadvantage of pour permeability is the problem of
runoff.Whenafabricdoesnotacceptwaterfreelyittends
to wash off the fabric taking any mulch covering, rock or
bark,withit.[7]
CONCLUSIONS
In Slovakia, energetic use of tirederived textile is still
preferred, mostly because of lack of knowledge of the
material recovery possibilities. The investigations of the
characteristics are required for understanding the basic
parameters of recycled fabrics from tirederived textile.
The most significant parameters of such fabrics are not
only the performance and the durability, but also the
environmental impact, mostly because of high zinc
content.
REFERENCES
[1] HAZARIKA, H., YASUHARA, K.: Scrap Tire Derived
Geomaterials Opportunities and Challenges,
ProceedingsoftheInternationalWorkshopIWTDGM
2007,Yokosuka,Japan
[2] HLOCH, Sergej, SODOMKA, Lubomr, VALEK, Jan,
RADVANSK,Agta:Struktura,vlastnosti,diagnostika
a technologie textili. 1. vyd. Preov, Vydavatestvo
MichalaVaka,2006,Pp.277,ISBN8080736685.
[3] JAMES, E. Mark, BURAK, Erman, FREDRICK, R. Eirich:
Science and Technology of Rubber, 1994 Academic
PressInc.
[4] LANGLEY, Kenneth D., WILSON, Alton R.,
COSKUNTUNAEsra:ManufacturingNonwovensUsing
Recycled Fibers, c2009 [cit. 20090305] Accessed at
WWW
<http://www.ntcresearch.org/pdf
rpts/AnRp98/f97d02.pdf>
[5] RADVANSK, Agta: Spracovanie odpadovch
pneumatk.In:Strojrstvo.vol.10,No.12(2006),pp.
6061. Internet: <www.strojarstvo.sk> ISSN 1335
2938.
[6] The construction of a tire [cit. 20120904] Accessed
at
WWW
<http://www.eng.buffalo.edu/courses/ce435/2001ZG
u/Firestone_Tires/FirestoneTiresReport.htm>
[7] WesternLandscapeandGeotextileSupply,c2009[cit.
20090304]
Accessed
at
WWW
<http://www.weedbarrier.com/>
[8] Wikipedia, Tire Manufacturing, c2009 [cit. 200902
13]
Accessed
at
WWW
<http://en.wikipedia.org/wiki/Tire_manufacturing>
150

TheProceedings
Manufacturing cost of Shell and Tube Heat Exchangers with paralel

Helical Tube Coils
IvanM.Rakonjac1StevanJ.Budimir2MarkoS.Jari3NikolaJ.Budimir3
1
ProjectManagementCollege,Krfska7,11000Belgrade,Serbia
InstitutGoa,MilanaRakia35,11000Belgrade,Serbia
3
InnovationCenteroftheFacultyofMechanicalEngineering,KraljiceMarije16,11000Belgrade,Serbia
2
ARTICLEINFO:
Abstract:
Correlation
Costs
Heatexchanger
Helicaltube
Manufacturing
Thepaperdealswiththemanufacturingcostsforshellandtubeheatexchangerswithparallelhelicaltube
coils.Themostcommoncorrelationsforestimatingpricesofshellandtubeheatexchangersfoundinopen
literatureweretestedusingthemarketdataforacomparisonandtheyhaveshownsignificantdeviations.A
new correlation for calculating prices of heat exchangers with helical tubes (when the shell is made of
carbonsteelandthehelicaltubeofcopper)wasdeterminedinthefollowingformCin=700+310.Shts.
Citation:RakonjacIM,etal.:ManufacturingcostofShellandTubeHeatExchangerswithparalelHelicalTubeCoils,2ndInternationalConferenceManufacturingEngineering&
INTRODUCTION
general case include costs of materials for apparatus,
energy,labor,andothercosts.
Shell and tube heat exchangers with parallel helical tube

coils(HEHTC)consistofalargenumberofhelicaltubecoils
whichareplacedwithinacylindricalshellintheformofa
tube bundle. The number of passes of fluid at the tube
side and at the shellside is usually one or two. The
number of passes of fluid at the tubeside is provided by
meansofbafflesallocatedinthestationaryheadchannel,
whereasthenumberofpassesoffluidattheshellsideis
providedbylongitudinalbafflesallocatedinthecylindrical
shell [1] [2]. 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
(Figure2)[2].
CALCULATIONPRICEOFHEATEXCHANGERS
We can find several correlations for estimating cost of
shell and tube heat exchangers in the open literature.
They are based on knowledge of the design of the
apparatus, the operating pressure, the heat transfer
surface, the material the apparatus is made of, etc. The
most often cited correlations are listed in Table 1, where
theyarenotgiveninitsoriginalform,butareadjustedin
order for the price to be expressed in an appropriate
manner(inthiscaseEUR2011).Pricesofapparatusshould
be translated also from the year in which they were
manufactured(Table2)intheyearforwhichtheanalysis
isdone.Thesimplestmethodwhichtakesintoaccountthe
increasing costs due to market trends, as given by the
equation:
C A / I A CB / I B
(1)
where
CA,priceofapparatusatthemoment,
CB,priceofapparatusatthemomentB,
IAindexofpriceatthemoment,
IBindexofpriceatthemomentB[3].
Fig.1 Shell and tube heat exchanger with parallel helical

tubecoilsfixedtubesheettype
ANALYSIS OF MANUFACTURING COSTS OF HEAT

EXCHANGERSWITHPARALLELHELICALTUBECOILS
Forheatexchangerswithparallelhelicaltubeswithafixed
tube sheet we encounter no correlation for the
assessment of investment costs in the literature.
Therefore,weconductedananalysisthegoalofwhichwas
todeterminetowhatextentthediscrepanciesarosewhen
using the existing equations (2 21). Deviation in prices
calculated using the correlation 2 21 and the actual price
of apparatuses (data obtained from the manufacturer) is
expressedusingstatisticalindicators:correlationratio(CR)
and the rootmean square deviation (RMSD), which are
alsoshowninTable3.
Fig.2 Shell and tube heat exchanger with parallel helical

tubecoilsfloatingheadtype
Althoughtheaforementionedheatexchangershavebeen
used in thermal engineering and process industries for
almosthalfacentury,problemsrelatedtotheireconomic
costs have not been fully explored. Taking this into
consideration, the primary objective of this paper was to
determinethemanufacturingcostsofshellandtubeheat
exchangers with parallel helical tubes. These costs in
151
IM Rakonjac, et al.
Manufacturing cost of Shell and Tube Heat Exchangers with paralel Helical Tube Coils
ab.1Correlationsforestimationpriceofshellandtubeheatexchangersbyvariousauthors
Year
Material
(ShellTube)
Temp.
range
( C )
Pressure
range
( bar )
Shts range
1990
CarbonsteelCarbonsteel
Correlation
( m 2 )
0.8
Cin 5910.69 303.98 Shts
Cin 7191.11 345.35 S
0.85
hts
0.91
hts
Ref.
Eq.
[4]
(2)
[4]
(3)
1990
CarbonsteelStainlesssteel
1990
StainlesssteelStainlesssteel
[4]
(4)
1990
CarbonsteelTitanium
0,92
Cin 11821,38 581.45 Shts
[4]
(5)
1990
TitaniumTitanium
0,93
Cin 14776, 72 590.22 Shts
[4]
(6)
Cin 8443.84 273.58 S
1995
0,05 0.27
1998
20 30
10 600
1998
CarbonsteelBrass
20 30
10 600
1998
20 30
10 600
1998
20 30
10 600
2001
350
10.5
9 6500
Cin 906.54 S
0.432
hts
0.64
hts
[5]
(7)
[6]
(8)
0.71
Cin 1278.15 S hts
[6]
(9)
Cin 1302.66 S
[6]
(10)
[6]
(11)
[7]
(12)
Cin 1400.41 S
0.86
hts
0.82
Cin 1874.35 S hts
Cin 8500.71 111.42 S hts

Cin 30800 3748 S
0.81
hts
2004
StainlesssteelTitanium
[8]
(13)
2007
300
50
0.68
Cin 3183.18 S hts
[9]
(14)
CarbonsteelAluminium
300
50
Cin 4138.14 S
0.68
hts
[9]
(15)
2007
CarbonsteelMonel
Cin 6684.68 S
[9]
(16)
300
300
50
2007
Cin 5411.42 S
0.68
hts
0.68
hts
[9]
(17)
300
50
Cin 9231.23 S
9 90
9 90
Cin 1957.79 S
9 90
2007
2007
2009
2009
Admiralty
2009
Copperbrass
50
Cin 1422.20 S
Cin 1722.68 S
0.68
hts
[9]
(18)
0.551
hts
[10]
(19)
0.679
hts
[10]
(20)
[10]
(21)
0.679
hts
ab.2ApparatusManufacturingyear
No.
S hts , m 2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
2.51
4.02
8.55
11.56
11.56
15.03
18.60
18.95
22.11
24.18
26.24
28.13
28.75
32.17
35.94
37.20
Manufacturingyear
Costofapparatusinmanufacturingyear
Costofapparatus 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
ab.3ApparatusManufacturingyear
No.
Year
1990
Material
(ShellTube)
CarbonsteelCarbon
steel
CarbonsteelStainless
1990
steel
StainlesssteelStainless
1990
steel
1990 CarbonsteelTitanium
1990
2
3
TitaniumTitanium
S hts
Temp.
range
( C )
Pressure
range
( bar )
range
( m2 )
Correlation
Ref.
CR
RMSD
Eq.
0.8
Cin 5910.69 303.98 Shts
[4]
0.4345
119.58
(2)
0.85
Cin 7191.11 345.35 Shts
[4]
161.19
(3)
Cin 8443.84 273.58 S
[4]
189.57
(4)
Cin 11821.38 581.45 S
[4]
332.1
(5)
Cin 14776.72 590.22 S
[4]
413.71
(6)
152
0.91
hts
0.92
hts
0.93
hts
IM Rakonjac, et al.
ab.3ApparatusManufacturingyear(continue)
No.
Year
Material
(ShellTube)
Temp.
range
(C)
Pressure
range
(bar)
1995
1998
Carbonsteel Carbon
steel
20 30
10 600
20 30
10 600
20 30
10 600
20 30
10 600
10.5
9 6500
1998
1998
10
1998
11
2001
12
13
14
15
16
2004
2007
2007
2007
2007
17
2007
18
2009
19
2009
20
2009
CarbonsteelBrass
Carbonsteel Stainless
steel
steel
Carbonsteel Carbon
350
steel
StainlesssteelTitanium
Carbonsteel Carbon
300
steel
Carbonsteel
300
Aluminium
CarbonsteelMonel
300
2.50 S hts 38, m 2
Cost of heat exchangers, EUR
[5]
49.47
(7)
[6]
0.6391
53.11
(8)
[6]
66.31
(9)
0.86
Cin 1302.66 Shts
[6]
154.62 (10)
Cin 1874.35 S
[6]
225.57 (11)
Cin 8500.71 111.42 Shts [7]
171.42 (12)
[8]
1266.65 (13)
[9]
275.04 (14)
[9]
386.68 (15)
[9]
684.66 (16)
[9]
535.64 (17)
[9]
982.76 (18)
0.432
Cin 906.54 S hts
0.64
Cin 1400.41 S hts
Cin 1278.15 S
0.71
hts
0.82
hts
Cin 4138.14 S
50
Cin 6684.68 S
50
50
0.81
hts
0.68
hts
0.68
hts
0.68
hts
0.68
Cin 5411.42 Shts
Cin 9231.23 S
50
9 90
0.551
Cin 1957.79 Shts
[10] 0.4072
9 90
Cin 1422.20 S
0.679
hts
[10]
0.679
Cin 1722.68 Shts
[10]
9 90
0.68
hts
70.7
(19)
70.24
(20)
104.51 (21)
CONCLUSION
The paper presents the main types and manufacturing
costs for shell and tube heat exchangers with parallel
helical tube coils. The cost analysis was conducted using
theactualprice(dataobtainedfromthemanufacturer)of
apparatuswithhelicaltubecoilsintheRepublicofSerbia.
After examining the correlations currently found in the
existingbodyofliteratureoninvestmentcostsofshelland
tube heat exchangers, it was concluded that a new
correlation needs to be found. 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
followingform
(2)
p 30 bar
Its statistical parameters are CR=0.9068 and
RMSD=17.10%. In the above equations (2 21) the value
of heat transfer surface (Shts) was expressed taking into
accounttheoutsideofthetube.
Cin 700 310 S hts , EUR

(3)
for range 2.50 S hts 38, m , and the operating pressure

p 30, bar . Statistical parameters of the equation are
2
20000
CR 0.907 ,andRMSD=17.10%.
18000
REFERENCES
16000
C in 700 310 S hts
14000
[1] Jensen, S., Heat exchanger Selection, CPEHeat

transferSurvey,1968.
[2] Jaric, M., Research On Thermal Performances And
Pressure Drop Of Shell And Tube Heat Exchangers
With Helical Tube Coils, PhD Thesis, Faculty of
Mechanical Engineering, University of Belgrade,
September,2011.
[3] Weidlicht, U., Gmheling, J., Modified UNIFAC Model
1., Prediction of VLE, hE and , Industrial &
EngineeringChemistryResearch,vol26,p.13721381,
1987.
[4] Taal, M., Bulatov, I., Klemes, J., Stehlik, P., Cost
estimation and energy price forecasts for economic
evaluation of retrofit projects, Applied Thermal
Engineering23(2003)pages:18191835
12000
10000
8000
6000
4000
2000
0
2
10
14
18
22
26
30
34
38
Heat transfer surface, Shts, m2
Fig.3 Manufacturing costs for apparatus versus to heat

transfersurface
153
Eq.
Cin 3183.18 S
RMSD
The analysis proved that these correlations show

significantdeviationsandthattheycannotbesuccessfully
used to describe the manufacturing costs for the
mentionedtypeofshellandtubeheatexchangers(aheat
exchanger with parallel helical tubes with a fixed tube
sheet, where the apparatus shell is made of carbon steel
and the heat exchangers tubes are made of copper).
Therefore, on the basis of the data given in Table 2 (for
2011 year price), a new correlation was found in the
followingform(Figure3):
Cin 700 310 Shts , EUR
CR
Cin 30800 3748 S
50
Ref.
Correlation
Carbonsteel Stainless
300
steel
300
steel
Carbonsteel Carbon
steel
Admiralty
Copperbrass
hts
range
2
(m )
0.05
0.27
IM Rakonjac, et al.
andChemicalEngineering,Vol23,No2,2004.pages:
89100
[9] WildiTremblay,P.,Gosselin,L.,Minimizingshelland
tubeheatexchangercostwithgeneticalgorithmsand
considering maintenance, International journal of
energyresearch,(2007);Volume31pages:867885
[10] Fesanghary, M., Damangir, E., Soleimani I., Design
optimizationofshellandtubeheatexchangersusing
global sensitivity analysis and harmony search
algorithm, Applied Thermal Engineering 29 (2009),
pages:10261031
[5] Vatavuk., W., A potpourri of equipment prices,

ChemicalengineeringAugust(1995)pages:6873
[6] Sinnott, K.R., Chemical Engineering Design, Vol 6,
ThirdEdition,ButterworthHeinemann,2003.Oxford.
[7] Loh, P., H., Lyons, J., White, W., C., Process
Equipment Cost Estimation, U.S. Department of
Energy, National Energy Technology Laboratory,
January2002.
[8] Reza,M.,H.,Reza,M.,O.,Shahi,P.,Hassan,M.,Cost
effective heat exchanger network design with mixed
materials of construction, Iran Journal of Chemistry
154

TheProceedings
Effect of Fly Ash Particles on the Mechanical Properties and

Microstructure on Compacted Magnesium Reinforced With SiC
Particles
RaviShankar1A.Manivannan2D.Vijayakumar3
1
St.PetersCollegeofEngineeringandTechnology,Avadi,TamilNadu,India,contactmail:raviannauniv23@gmail.com
DepartmentofMechanicalEngineeringAnnaUniversityofTechnologyTirunelveli,TamilNadu,India
MultitechDr.RangarajanDr.SakunthalaEngineeringCollege,Avadi,Chennai,TamilNadu,India,vijiaji@gmail.com
2
3
ARTICLEINFO:
Received:20August2012/Revised:12November2012/Accepted:18November2012
Abstract:
Greensandcompaction
Flyash
Microhardness
Thermalcycling
Opticalmicroscope
Metal matrix composites are used mostly in space ships, aerospace, automotive, nuclear, biotechnology,
electronicandsportinggoodsindustries,butduetotheirhighcost,experimentsareusuallydonetoreduce
thecostofthecompositesandinexpensivematerialsareutilizedformetalmatrixcomposites.Flyashisone
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. So, composites with fly ash can be used to
reducethecostofthemetalmatrixforapplicationsinautomotiveandsmallengineapplications.Thiscould
be achieved by reinforcing the Mgcomposites with a high strength component. This work aims to
experimental evaluation of thermal behavior of Mgcomposites reinforced with SiC in addition with
variation of fly ash. Magnesium reinforced with SiC particles were prepared by powder metallurgy
technique.Furthermorethemicrostructuralanalysisandmicrohardnesstestwerecarriedouttoseethe
behaviorofmaterialpropertiestowardsheatingandcooling.Itisfoundthatthereisnoreactionandgrain
growth in the specimen prepared. The micro hardness of composite increased by 30 % than that of
aluminum composite. Wear rate shows a greater improvement of 10% wear resistance than that of
aluminumcomposite.
Citation:ShankarR.etal. EffectofFlyAshParticlesontheMechanicalPropertiesandMicrostructureonCompactedMagnesiumReinforcedWithSiCParticles,2ndInternational
INTRODUCTION
To realize the application of the light Mgalloys, the
strengthatelevatedtemperaturesandtheelasticmodulus
of these should be improved. This could be achieved by
reinforcing the Mgcomposites with a high strength
component. It can be done by reinforcing ceramic
particles,continuousfibersorshortfibersfromAl2O3,SiC
orC.Withapplyingofreinforcementintheformoffibers
or particles, particularly for reciprocating components, a
weight saving optimization should be taken into
consideration that leads to the selection of carbon fibers
instead of ceramic fibers. The literature survey is carried
outasapartofthethesisworktohaveanoverviewofthe
production processes, properties and wear behavior of
metal matrix composites. Composite structures have
shown universally a savings of at least 20% over metal
counterparts and a lower operational and maintenance
cost [1]. As the data on the service life of composite
structuresisbecomingavailable,itcanbesafelysaidthat
they are durable, maintain dimensional integrity, resist
fatigueloadingandareeasilymaintainableandrepairable.
Compositeswillcontinuetofindnewapplications,butthe
largescalegrowthinthemarketplaceforthesematerials
will require less costly processing methods and the
prospectofrecyclingwillhavetobesolved.Badinietal.
[23] studied the thermal fatigue behaviour of a
2014/Al2O3SiO2(Saffilfibers)compositeprocessedby
squeeze casting. Thermal fatigue behaviour of a
2014/Saffil composite has been investigated. This
composite was produced by infiltration of preforms of
Saffil fibers (Al2O3SiO2 fibers) with a 2014 aluminium
alloy (Al4.7Cu1.0Si0.6 Mg). Thermal cycling tests
wereperformedonspecimens(eitherasfabricatedor
intheT6temper)inthetemperaturerangebetween
25and220C.After1000cyclesboththemicrostructure
155
and the mechanical characteristics of the composite

sampleswereinvestigated.ClineA.Mahieuxetal.[5]
have studied the effect of temperature on polymer
matrix composites.Mechanical, electrical and optical
propertiescanundergoorderofmagnitudechangesovera
100Ctemperaturechangeandmoisturediffusioncan
vary by as much as three orders of magnitude.
Generally speaking, the rearrangement rate increases
withtemperature.Elomarietal.[9]havestudiedthe
Thermal Expansion behaviour of particulate metal
matrix composites. Aluminiummatrix composites
containingthermallyoxidizedSiCparticlesofcontrolled
diameter ranging from 3 to 40 m have been
producedsuccessfullybyvacuumassistedhighpressure
infiltration. Their thermalexpansion coefficients (CTEs)
were measured between 25 and 500 C with a high
precision thermal mechanical analyser (TMA), and
compared with the predictions of various theoretical
models. Han et al. [16] studied the effect of
reinforcementsizeontheelevatedtemperaturetensile
propertiesandlowcyclefatiguebehaviourofparticulate
SiC/Al composites. The cyclic stress response
characteristics and lowcycle fatigue endurance of
powdermetallurgyprocessed
commercially
pure
aluminiumcompositesreinforcedwithSiCparticlesof
different sizes and of the unreinforced matrix were
studiedunderarangeofcyclicplasticstrainsat441K.At
elevated temperature the composites and unreinforced
aluminium alloy definitely show cyclic softening.
Hosking, F. Folgar Portillz, R. Wunderlin and R.
Mehrabian [29] studied Composites of aluminium
alloys.fabricationandwear behaviour.processesfor
fabrication of aluminiumalloy composites containing
paniculatenonmetals,thenetshapeformingofthese
R. Shankar, et al.
Effect of Fly Ash Particles on the Mechanical Properties and Microstructure on Compacted Magnesium Reinforced With SiC Particles
composites, their microstructures, their friction and

wearbehavioursandtheirmechanicalpropertiesare
described.Compositesoftwowrought(2014and2024)
andonecast(201)aluminiumalloyscontaining2to
30wt%ofAl2O3andSiCparticlesinthesizerangeof
1to142mwereprepared.Thenonmetallicparticles
were added to a partiallysolid vigorouslyagitated matrix
alloy.Theparticleswerethenretainedinthematrixuntil
interface interaction, for example, the formation of
MgAl2O4 spinel in the case of Al2O3 particles, were
faciliated. These composites were solidified and
subsequently reheated to above their liquidus
temperature and formed under high pressure in a
closeddieforgingtypeofapparatus.Compositeswith
particulateadditionsofsizelargerthan5mpossessed
homogeneous structures; particles of size 1 m,
however,tendedtocluster.Thewearbehaviourofthe
compositeswasstudiedusingapinondisctypemachine.
Itwasshownthatcompositescontaininglargeamountsof
nonmetals, 20 wt%, exhibit excellent wear resistance
whilst those with small to moderate amounts of non
metals possess tensile properties comparable to the
matrix alloy. Increasing the amount of particulate
additionsresultsinreducedductility.Finally,amethod
wasinvestigatedofproducingcomponentswithhigh
weightfractionsofnonmetalsneartheirsurfaceInpast,
significant work has abeen done on production and
characterization of MMCs using different methods. A
number of researchers have done experimental analysis
on composites subjected to thermal cycling, but the
effectsofthermalcyclingonAluminiumcompositesusing
SiCandFlyashtogetherhavenotbeeninvestigated.The
present work will focus on fabrication and
characterizationofAlmatrixcompositereinforcedwith
varying quantities of SiC and Flyash. Huang et al. [20]
investigated on Investigated on thermal fatigue of
aluminiumandmagnesiumalloybasedcomposites.Both
theKS1275pistonandAE42alloysandtheircomposites
have realistic and/or potential applications as engine
components in the automotive industry. Used as
engine components, the dimensional stability is of great
concern. Thermal cycling experiments can simulate the
serviceconditionsofthematerialsandgiveanevaluation
how the dimension changes during their service in the
changing temperature environments. The present paper
investigates the thermal fatigue of the short fiber
reinforced KS1275 piston and AE42 alloys, with an
emphasisonthechangesinthestrainandhardness
before and after thermal cycling. Huang et al. [22]
studiedthethermalbehaviourofshortfiberreinforced
AlSi12CuMgNi piston alloys. This work investigated both
theagingandthermalcyclingbehavioursoftheshortfiber
reinforced AlSi12CuMgNi piston alloys using Xray
diffraction,microhardnessandthermaldilatometrytests.
The magnesium is essential for the formation of
strengtheningprecipitates,butitcoulddepletedueto
itsreactionwiththeSiO2inthefiberorinthebinder,and
therefore the age hardening could be suppressed. The
coefficientofthermalexpansion(CTE)isaffectedbyboth
the microstructure and internal thermal stresses
generated from the both heating and cooling. The
experimental results show that during thermal cycling up
to 47 times the stress relaxation proceeds through the
plastic deformation and matrix recovery. Jansson et al.
[17]studiedtheTransverseandCyclicthermalloadingof
thefiberreinforcedmetalmatrixcompositeSCS6/Ti15
3.ThetransversepropertiesofaSiCfiberreinforced
Ti alloy matrix composite subjected to transverse
mechanical and cyclic thermal loading have been
investigated.Fibersandmatrixhaveamismatchinthe
156
coefficientsofthermalexpansionthatinducesthermal
stresses in addition to those caused by mechanical
loading.Mykuraetal.[13]havestudiedtheThermal
Expansion and stress relaxation of metalmatrix
composites.Thecoefficientofthermalexpansion(CTE)
of a series of Al6%Si matrix samples, with
reinforcements of carbon, SiC, Al2O3, or boron fibres,
cloths, or ceramic particles was measured in the range
60220C with a dilatometer. Pickard, S.M et al. [24]
studiedthebehaviourofmetalmatrixcompositesduring
temperature cycling. Commercial purity aluminium
reinforcedwithSiCparticleshasbeenusedtomodel
thebehaviourofmetalmatixcomposites(MMCs)during
thermal cycling. Above critical temperature amplitude of
about 150 degC an acceleration in creep under the load
occurs. This is accompanied by a reduction in the creep
stress exponent from 15 to 1. The reduced stress
exponent leads to a superplastic deformation behaviour
withextensionsinexcessof150%recorded.Transmission
electron microscopy studies of the deformed
microstructures show an essentially constant dislocation
structurebetweenasreceivedMMCsandthoseafter90%
strain. Ponter et al. [15] have studied the on the
behaviourofmetalmatrixcompositessubjectedtocyclic
thermal loading. The mechanical properties of metal
matrix composite materials are strongly affected by
thermal cycling. Through the study of experimental
data, for an aluminium / alumina continuous fibre
composite, the paper investigates the relationship
between the observed behaviour and the predictions,
using simplified methods of analysis, of classical
plasticity models for the matrix material. Ponter et
al.[14] have studied the bounding properties of metal
matrix composites subjected to cyclic thermal loading.
Thepaperisconcernedwiththeloadbearingcapacityof
a body with a regular periodic microstructure with
elasticandelasticperfectlyplasticphases,suchasa
metalmatrixcomposite,whensubjectedtocyclicthermal
loading.PramilaBai,B.S.RamaseshandM.K.Surappa[26]
presented the theory that Aluminium alloy (A356)SiC
composites containing 15 and 25 wt.% silicon carbide
particles(averagesize43m)weretestedforslidingwear
atdifferentloadsusingapinondiscmachine.Composites
exhibited better wear resistance compared with
unreinforcedalloyuptoapressureof26MPa.Scanning
electron microscopy examination of worn surfaces and
sub surfaces show that the presence of dispersed SiC
particleshelpinreducingthepropensityofmaterialflow
at the surface, at the same time leading to the
formationofanironrichlayeronthesurface.Transition
wear behaviour of SiCparticulate and SiCwhisker
reinforced7091AlmetalmatrixcompositesQin,S.Y.He
et al. [10] studied the Effect of thermalmechanical
cyclingonthermalexpansionbehaviourofboronfiber
reinforced aluminium matrix composite. The thermal
expansionbehaviourofboronfiberreinforcedaluminium
matrixcompositesubjectedtothermalmechanicalcycling
(TMC) was studied. Experimental results showed that
TMCaffectedgreatlythethermalexpansionbehaviourof
the composite. Using a simple analysis model of
internalstressinthefibers,thestresschangeduring
thethermalexpansioncoefficientmeasurementsofthe
compositesubjectedtoTMCwascalculated.Theresults
indicated that TMC could induce the interfacial
degradation of the composite, and the more the
numbersofTMCcycles,orthehighertheappliedstress
level of TMC, the more serious the interfacial
degradationofthecompositebecame.Theproposedone
dimensionalanalysismodelwasprovedtobeasimpleand
qualitativeapproachtoprobingtheinterfacialdegradation
ofunidirectionalfiberreinforcedmetalmatrixcomposites
during TMC. Rajendra U Vaidya et al. [6] studied the
thermal expansion of various fiber and particle
reinforced metalmatrix composites has been measured
and the experimentally obtained values compared with
the predictions of various theoretical models. The
particulate composites exhibited some residual strain
when cooled down from the peak temperature to room
temperature.Themagnitudeofthisstrainwasafunction
ofthepeaktemperatureandnumberofthermalcycles.
These composites exhibited very small residual strains
when cooled down from the peak temperature to
roomtemperature.Inaddition,thethermalexpansion
response was not linear over the test temperature
range but exhibited regions of distinctly different
slopes. Shipway, A. R. Kennedy and A. J. Wilkes[25] has
studiedthatTiCreinforcedMMCshavebeenproducedin
a range of aluminium alloys using a novel casting
techniquewhichresultsinspontaneousincorporationof
the particles into the melt and thus strong bonding
between the particles and the matrix. The sliding wear
behaviouroftheextrudedcompositeshasbeenstudiedas
a function of load and particle volume fraction and has
been compared with a commercially available SiC
reinforced composite. In all cases, alloy reinforcement
resultedinareductioninwearrateandanincreasein
theloadatwhichthetransitionfromlowratewearto
highratewearoccurred.Inthelowratewearregime,
the wear coefficients of all the alloys in both the
reinforced and unreinforced states were similar, and
sincetheTiCreinforcedA356alloywasthehardest(due
inparttothegrainrefiningactionofTiC),itexhibitedthe
lowestwearrate(lowerthanthatoftheSiCreinforced
composite). Wear of the steel counterface depended
on the mechanism of wear of the composite. An
increase in load generally resulted in an increase in
wear rate of both the composite pin and counterface,
and the reasons for this are presented. Increasing the
volume fraction of particles in a composite reduces its
wear rate but generally increases the wear rate of the
counterface. It is suggested that when both
counterface and composite wear are considered, an
optimumvolumefractionofparticlesexistsatwhichwear
is lowest. Tan et al. [19] have studied the Thermal
Cycling processes in metalmatrix composites. In this
work,astudyofthebehaviourofAA6061reinforced
with alumina particles produced by casting and
extrusion,undertheactionofstraincontrolandthermal
cycling conditions, is presented. Comparisons are made
withunreinforcedAA6061matrix,andalsowiththesame
composite reextruded to obtain finer grain sizes.
Elongationsobtainedviathermalcyclingarecompared
with those from room temperature and isothermal
testing.Theworkalsolooksatthedifferencesincycling
atdifferentfrequencies,rangeandrate,fortheAA6061
matrixcomposites.WangandH.J.Rack[27]studiedthe
wear behaviour of unreinforced and reinforced 7091
Al, the latter containing either 20 vol.% SiC particulates
(SiCp) or 20 vol.% SiC whiskers (SiCw), was studied as a
functionofslidingdistanceandslidingvelocityunder
unlubricatedconditions.Atslidingvelocitiesbelow1.2m
s1, SiC reinforcement does not affect wear resistance.
Wear debris produced from both the unreinforced and
reinforced materials was predominantly metallic and was
small in dimension and dark in color. The mechanism of
wear under these conditions was surfacefatiguerelated
surface cracking. At sliding velocities greater than 1.2 m
s1,thewearratesofthereinforcedmaterialswerelower
than for the unreinforced matrix. Both the unreinforced
alloy and the SiCreinforced composites exhibited
157
R. Shankar, et al.
elevatedwearratesduringtheinitialperiodofsliding,
the mechanism of wear under these conditions, i.e
high velocity and short sliding distance, being
controlled by subsurfacecrackingassisted adhesive
transferandbyabrasion.Duringsteadystatesliding,
these elevated wear rates were maintained by the
unreinforced alloy, reduced wear rates being observed in
the reinforced composites. The initial wear rates of the
composites depend strongly upon reinforcement
orientation, the highest wear rates being observed the
perpendicularlyorientedSiCwcomposite.However,the
steady state wear rates of the composites were
generally independent of reinforcement geometry
(particulatevs.whiskers)andorientation(perpendicular
vs.parallel)withtheexceptionofwearat3.6ms1
where the paralleloriented SiCw composite was
superior.WilsonandA.T.Alpas[28]studiedtheEffectof
temperatureontheslidingwearperformanceofAlalloys
and Al matrix composites. The effect of ceramic
particulate and graphite additions on the high
temperaturedryslidingwearresistanceoftwoAlalloys
was studied. The experiments were performed using a
ringonflat sliding contact against hardened SAE 52100
bearing steel counterfaces on an apparatus built for
testing at controlled temperatures. Conditions were
selectedsuchthatthematerialsincontactwerekept
in an isothermal atmosphere and the generation of
frictional heat was minimised by the use of a low load
(11.55N)andslidingspeed(0.1ms1).Forunreinforced
6061AlandA356Alalloysatransitionfrommildtosevere
wear occurred in the ranges 175190 C and 225230 C
respectively. With the addition of 20 vol.% Al2O3 to
6061Al,themildtosevereweartransitionwasraised
to a range between 310350 C. Likewise, an addition of
20vol.%SiCtotheA356Alincreasedthistransitionto
440450C.AhybridA356Alcompositecontaining20
vol.%SiCand10vol.%graphiteremainedinamild
wearregimeatthehighesttesttemperatureof460
C. All the reinforced alloys were able to withstand
considerablethermalsofteningeffectswhileremaining
inamildslidingwearregime.Thisisattributabletothe
formation of protective transfer layers of comminuted
reinforcing particulates and transferred steel debris
from slider counterfaces. Graphite in the hybrid
compositeintroducedgreatermildwearlossescompared
with the other composites due to increased friability
and contact surface extrusion effects. The absence of
severe wear phenomena in this composite contributes to
the inhibition of comminution and fracture by graphite
entrainedinthesurfacetribolayer.
PROBLEMFORMULATION
Inpresentwork,theEffectsofflyashonCompactedMg
SiCfly ash Composites are investigated. Metal matrix
composites (MMCs) are a range of advanced materials
that can be used for a wide range of applications within
the aerospace, automotive, nuclear, biotechnology,
electronic and sporting goods industries and are rapidly
becoming candidates as structural materials for high
temperature applications. There has been an increasing
interestincompositescontaininglowdensityandlowcost
reinforcements.
Among
various
discontinuous
reinforcements used, fly ash is one of the most
inexpensive and low density reinforcement available in
large quantities as solid waste byproduct during
combustion of coal in thermal power plants. Hence,
composites with fly ash as reinforcement are likely to
overcomethecostbarrierforwidespreadapplicationsin
automotive and small engine applications. Material
selected for experimental Purposes was Mg/SiC 15p.The
R. Shankar, et al.
helpof100,220,500,800,1000&1500mgritsizeemery
paper.Loadusedonmicrohardnessmachineusedwas.1
N.
Slidingwearbehavior
Abrasive wear has been defined as the displacement of
material caused by hard particles or hard protuberances
wherethesehardparticlesareforcedagainstandmoving
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
size10mmdiameterpreparedfromcompositecastingwas
loaded through a vertical specimen holder against
horizontalrotatingdisc.Beforetesting,theflatsurfaceof
thespecimenswasabradedbyusing2000mgritpaper.
The rotating disc was made of steel of diameter 50mm
and hardness of 64 HRC. The principal objective of
investigationwastostudytheeffectofvariationofnormal
load,slidingvelocityandpercentageSiConwearrate.
additionofFlyAshisdonetoitin5%,10%and15%,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
differenttestsareperformedonspecimensafterthermal
cyclingtofindchangeinpropertiesofmaterial.
OBJECTIVEOFWORK
Toseeeffectofflyashparticlesonspecimens,whichare
prepared by varying the fly ash content in original
material.Ininitialstagethespecimenareproducedusing
powder compaction technique. Different tests are
performedonthesetestsamples.Thespecimensarethen
subjected to varying temperature 100 C to 450C and
changesinthepropertiesofthespecimensareobserved.
Thetestsperformedonthesamplesareasbelow:
1.MicroHardnessTest.
2.TheMicrostructure.
3.WearTest.
4.DifferentialScanningCalorimeter(DSC).
EXPERIMENTALPROCEDURE
Materials
In this study, elemental magnesium turnings of 99.5%
purity(suppliedbyMERCK,Noida,INDIA)wereusedasthe
basematerialandsiliconcarbideparticulates(MICROFINE
CHEMICALSCHENNAI)withanaveragesizeof0.6lm,were
used as ceramic reinforcement. Fly ash from India
Cements, Sankar Nagar is collected for experimental
purpose.
SamplePreparation
ThesampleispreparedbyfillingtheMagnesiumintheDie
consideringthetotalvolumeaccommodatedtobe100%
volumebyMagnesium.Thesamplesarepreparedthenby
mixing the proper proportion of Magnesium, Silicon
CarbideandFlyash.Themixedcomponentisfilledinthe
Die with which the die is made with three segmented
parts.TheTopcomponentofthedieismadeofstainless
steel. The bottom two components are made of carbide
on the inner part of the component which is highly
polished.ThepolishedareaiscoatedwithGraphiteorZinc
striatefortheeasyremovalofthematerialfromthedie.
After filling the material in the die the top punch covers
thematerialforhighpressurecompactionofthematerial.
Thelowdensitymaterialisusedsotherecouldbenoneed
forheavyloadforcompactingthematerial.
IsothermalHeattreatment
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
andwrappedinaluminumfoiltominimizereactionofthe
Mg/SiC composite with oxygen present in the furnace
atmosphere.
MicroStructuralCharacterization
Theextrudedrods,bothheattreatedandunheattreated
weresectioned,metalographicallypolishedandexamined.
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
Imagingsoftware.
Microhardness
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
requiresametallographicfinishanditwasdonewiththe
Fig.1Weartest(PinandDiscArrangement)
OpticalMicroscopyExamination
Microstructurewasvisualizedwiththehelpofanoptical
microscope. For the sample preparation first all the
sampleswerecutdownintosmallcuboidsshapesthenthe
sampleweregrindedondifferentgradesofgritsizepaper
sequentially by 180, 220, 320, 400, 600, 1000, 1500 and
2000m.Aftergrinding,thesampleswerepolishedusing
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
exhibitingequiaxedgrains.Theresultsindicatenochange
in grain morphology as a result of heat treatment. Fig. 2
shows an optical micrograph of the asprepared
Mg/SiC/Fly ash composite. The SiC particles are not
uniformly distributed in the matrix; they form in many
casessmallclusters.ThemeanSiCparticlesizewasfound
to be about 9 m. As it is visible from Fig. 2, the heat
treatedspecimenappearsmainlyconstitutedofverysmall
equiaxed grains (generally 3m) after accurate optical
microscopy observations. No grain growth has been
observed during the deformation tests at elevated
temperatures.
158
R. Shankar, et al.
compositesandunreinforcedspecimensunderdrysliding
conditionarepresented.
Fig.4Wearofreinforcedcompositeatappliedloadof29.4
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
differentappliedloads:29.43N(3kgf),39.24N(4kgf).From
figure 4 the average wear rate between each composite
withrespecttoitsslidingdistanceisabout.021mm3/min.
As observed from wear tests, addition of fly ash to
specimen in higher percentage decreases their wear
resistance.Butwhenthespecimensweretestedforafter
termalcyclingtheresistancetowearofspecimennumber
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
Figure4thewearrateincreasegraduallyduetothefewer
loadappliedinthespecimen.
Fig.2 Optical micrograph of the heat treated Mg/SiC/Fly

ash10pcomposite.
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
SiCparticulateandthusnothavinganyreaction.
Fig.3 Optical micrograph of the heat treated Mg/SiC/Fly

ash10pcomposite.
There was also no evidence of surface oxidation of heat
treated rods, indicating that the graphite coating and
aluminum wrapping were eective in shielding the rods
fromoxidation.
WearTestCharacteristics
The sliding experiments were conducted in air at room
temperature in a pinondisc wear testing machine. The
pinswereloadedagainstthediskbyadeadweightloading
system.Thepinspecimenswereflatendedpinsof10mm
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
hardnessHV256.Beforetheweartest,eachspecimenwas
groundby1maluminapowderandthecounterdiscwas
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
loadsof29.43N(3kgf)and39.24N(4kgf)foratotalsliding
distance2400mataconstantslidingspeedof2.09m/sfor
all sample. During the tests the relative humidity and
temperature of the surrounding atmosphere was about
50% and 25C respectively. The test duration was
15minutes at a constant disc speed of 400rpmfor all the
tests. The wear test results of the Magnesium hybrid
Fig.5 Wear of reinforced composite at applied load of

39.24N
The results indicate that the volume content of the
particulatereinforcementhasamarkedeffectonthewear
rate.Thewearrateofthecompositespecimensdecrease
with increasing volume percentage of particulate
reinforcement.Asexpected,thewearrateofacomposite
specimen with a fixed volume percentage of
reinforcement increases with sliding distance (fig.5). At
constantappliedload,thecompositespecimensexhibita
lower wear rate compared with the unreinforced alloy.
The addition of SiC and there will be some of these
particlesmaybeformedinclusteratthemajorendofthe
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
reinforcementhasamarkedeffectonthewearrate.The
wear rate of the composite specimens decrease with
159
R. Shankar, et al.
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
thermograms.Thepresenceofthesepeaksinthethermo
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
inhibitsthedissolutionofphaseinMg.Theendothermic
reactionlabeledbcanbeseenintheMMCsbetween90
and456oC.Thispeakismostlikelyduetoanendothermic
dissolutionreactioninthecomposites.
increasing
volume
percentage
of
particulate
reinforcement.Asexpected,thewearrateofacomposite
specimen with a fixed volume percentage of
reinforcement increases with sliding distance (Fig.5). At
constantappliedload,thecompositespecimensexhibita
lowerwearratecomparedwiththeunreinforcedalloy.
MicroHardnesstest
Composite samples show higher hardness than that of
their unreinforced counterparts (Chart 1). The composite
sample(4)with15micrometersizeparticlesshowshigher
matrixhardnessvaluethanthatofthecompositesample
(2) with 150 micro meter size particles. The micro
hardnessneartheparticle/matrixinterfaceishigherthan
thatofinteriorregionofthematrixinallthecases.
Fig.6 Micro hardness value before and after thermal

CyclingWear of reinforced composite at applied load of
39.24N
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.AdditionofFlyashparticlesupto20%resulted
inanincreaseinmicrohardnessofspecimens.
DifferentialScanningCalorimetry
Figure 7 shows typical DSC thermo grams obtained for
highpurity Magnesium and SiC in the temperature range
16to500oC.Theexpandedviewsofthedifferentsections
o
ofthethermogramsareshown.Thedatabelow16 Cand
o
above500 Cwerenotpresentedbecauseofthermallag
in the DSC equipment during measurements. As can be
seen from Figure 7, the peak of the exothermic reaction
labeledaoccurredatabout89.4 o CinMg/SiCcomposite.
The presence of 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
phaseandhighpurityofMginthecomposite.Thispeakis
duetomeltingofthealloyasitoccurredwithinthesame
temperaturerangeasthoseofhighpuritymagnesium.
0
Fig.9DSCthermogramofMg/SiCbetween96to410 C
Fig.10Temperaturechangewithrespecttotime
Figure 10 shows the DSC thermo grams of Mg and the
composites coplotted with that of fly ash for samples
heatedfrom100to500oC.Ascanbeseen,flyashshowed
Fig.7DSCthermogramofMg/SiC
160
Fig.8DSCthermogramofMg/SiCbetween96to4100C
Figure 9 shows the DSC thermo grams of Mg and the
composites when cooled from 500 to 100 o C. The
expandedviewsofdifferentsectionsareshown.Itcanbe
seenfrom that some of the phase changes that occurred
duringheatingdidnotreoccurduringcooling.Thiscanbe
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
temperaturesobtainedduringheating.
no detectable reaction peak in the temperature range

studied.Therefore,itcanthenbeconcludedthatitisdue
to the dissolution of the phase that formed between fly
ashandMgduringfabrication.
Fig.11DSCthermogramofMg/SiCbetween16to4750C
Figure 11 shows the thermo grams of Mg and the
compositescoplottedwiththatofMgSiCflyashmixture.
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
200and400 o Cinthemixturecouldbeattributedtothe
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
transformationintheMgSiCflyashmixturesampleasits
possiblecause.
R. Shankar, et al.
that the endothermic peaks observed in the samples at

about 376.14o C were due to a reversible dissolution
reactionintheMMCs.
CONCLUSION
From the experiments carried the following conclusions

havebeenderived:
1. Thespecimenwith20%flyashContentwerefound
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/flyash15pspecimentested.
2. TheOpticalimagesrevealedthatbothSiCandflyAsh
particlesarewelldistributedinMagnesiumMatrix.
3. With the addition of fly ash with higher
percentage the rate of heat transfer from
specimens decreases as revealed by temperature
timeplotforheatingandcooling.
4. Increase in area fraction of reinforcement in matrix
resultinimprovedhardnessvalues.
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
microhardnessofspecimens.
6. WiththeadditionofflyashtoMgSiCthewear
resistanceofthecompositedecreasedwhichisdue
to the clusters of SiC particles in the specimen. The
specimenwithhighestpercentageofflyashworn
out more rapidly as compared to the other
specimensduringweartest.
7. DuringtheDSCtesttheendothermicreactionoccurs
with a maximum peak and area of heat transfer of
376.24oC and 150 J/g respectively which shows the
heatisabsorbedbytheflyashparticles.
ACKNOWLEDGEMENT
TheauthorsaregratefultoDr.K.V.RamaofIITMadrasfor
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
AnnaUniversityofTechnologyTirunelveliforbringingout
valuable informations and Dr K.Purushothaman of
St.PetersCollegeofEngineeringandTechnologyChennai.
Fig.12DSCthermogramofMg/SiC/flyash20pbetween10
0
to490 C
Figure 12 shows the thermo grams of Mg and the
compositescoplottedwiththatofMgSiCflyashmixture
o
on heating from 16 to 500 C and showing theexploded
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
likelyduetomeltingofeitheraluminumormagnesiumin
the mixture and the differences observed between the
peakpositionsofthemixtureandMgcouldbeattributed
tothepresenceofotheralloyingelementsinMg.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.Thepeaklabeledb'atabout376.14oCinthe
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
SiCfly ash mixture occurred at about the same
temperature asthose of the test materials. This confirms
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TheProceedings
Perishable Product Scheduling on Single Machine with Deadlines

NargessShirvani1RubnRuiz2andShahramShadrokh3
1
IndustrialEngineeringDepartment,SharifUniversityofTechnology,Tehran,Iran,shirvani@mehr.sharif.ir
GrupodeSistemasdeOptimizacinAplicada,InstitutoTecnolgicodeInformtica,CiudadPolitcnicadelaInnovacin,Edifico8G,Acc.B.Universitat
PolitcnicadeValncia,CaminodeVeras/n,46022Valencia,Spain,rruiz@eio.upv.es
3
IndustrialEngineeringDepartment,SharifUniversityofTechnology,Tehran,Iran,shadrokh@sharif.edu
2
ARTICLEINFO:
Abstract:
Singlemachinescheduling
Perishableproducts
Deadlines
Releasedates
Schedulingtimewindows
This paper studies a realistic single machine scheduling problem in presence of highly perishable products that
need to be delivered on time to customers. Jobs must be produced during an allowed time window which is at most
of shelf life length and ends at the deadline. A revised WSPT rule is proposed and the noncyclic problem is solved
by a two-phase algorithm. It is also verified that the cyclic version comprises some independent noncyclic problems.
Numerical experiments reveal the efficiency of the proposed solutions for solving the tested instances. Furthermore,
the results verify that cyclic schedules increase flexibility and the manufacturers ability to satisfy customers orders.
Also in some instances, cyclic schedules dramatically decrease the total cost.
Citation:ShirvaniN,RuizR,ShadrokhS. PerishableProductSchedulingonSingleMachinewithDeadlines,2ndInternationalConferenceManufacturingEngineering&Management2012,
(2012),p.163166,ISBN9788055312163
INTRODUCTION
are to investigate both the noncyclic and the cyclic
versionsoftheproblem.Therestofthepaperisorganized
as follows. In Section 2 we describe the problem and the
notation.Section3isdedicatedtothedevelopmentofan
algorithm for the problem with limited time horizon. In
Section 4 the cyclic version of the problem is discussed.
Section5istoillustratethenumericalexperimentandthe
last section concludes the paper and suggests topics for
futureresearch.
The single machine scheduling problem deals, in its

simplest form, with the sequencing and scheduling of
differentjobsonasinglemachine.Thisproblemhasbeen
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
producedanddeliveredbasedoncustomersorders.Since
thefinishedproductsarehighlyperishable,storageinthe
productionsiteforlongerthanshelflifeisnotpermitted.
This problem is a typical scheduling subject in fresh food
and dairy industries. Additionally, when production is
performed between independent parties in a chain,
coordinators of different stages may be faced by such a
problem. There is an abundance of published researches
considering single machine scheduling subject to due
dates or deadline constrains and earliness/tardiness
penalties. Cheng and Gupta (1989) [1] and Baker and
Scudder (1990) [2] provide a review on scheduling
problems involving due dates and earliness/tardiness. In
the classic form of the problem, a job is expected to be
completedexactlyatitsduedate.Earlyorlateproduction
imposes earliness or tardiness costs, respectively.
Extended forms of the problem have been widely
investigated by researchers. Some papers consider an
intervalcalledduewindowratherthanduedate.Anger
etal.(1986)carriedoutthefirstduewindowstudy[3].[4],
[5] and [6] are instances of recent studies on this area.
Assignable due window is another extension in the
classic form in which the early and late due dates are
treatedasdecisionvariables.Wereferreadersto[7]and
[8] as examples of this subject. Huo et al. (2010) have
investigatedafactorythatmanufacturesperishablegoods
while considering a time window for a safe completion
timeofproducts[9].Inthecurrentresearch,wefocuson
the scheduling of perishable items that should be
processed before the given deadlines. The final products
are highly perishable and storing them in the production
site incurs in a holding cost, also the manufacturer is not
allowed to hold them for more than the given post
productionshelflife.Inourstudy,theschedulingwindow
is the only feasible scheduling interval and jobs are not
allowedtobecompletedoutsideofthiswindow.Herewe
NOTATIONANDPROBLEMDESCRIPTION
Inthecurrentresearch,asinglemachineisconsideredto
process a set 1,2, , of different jobs in a time
horizon of length . Each job needs a given
processing time and has a fixed deadline . All the
jobs must be processed before the given deadlines. Early
jobscanbeheldintheproductionsitewithaholdingcost
, but job cannot be stored for more than units of
time. Hence the feasible region for the completion of
to . In the other
every job is limited from
words, beside the deadlines, the jobs are subject to an
) which is known
earliest possible start time (
asreleasedateofthejobintheliterature.Deadlineofjobs
are grouped into distinct sets where
and ,
0
1, 2, , showthedistinctivedeadlines.
is also considered as a dummy deadline in the noncyclic
problem. As an example suppose an instance problem
with5jobssuchthat
2,
4and
6. In this problem
3 and 2, 4, 6 are considered as
distinctdeadlines.Thejobsshouldbescheduledinsucha
way that minimizes the total holding cost while adhering
to the release dates and deadlines constraints. Two
differentversionsoftheproblemhavebeenconsidered.In
thefirsttype,weconsiderashorttimeschedulingperiod
and plan the jobs in a limited time horizon. However, for
the companies that produce dairy products or the ones
that have long term contracts with retailers, the
productionorderscomeupiterativelythroughthecycles.
Thesemanufacturersareusuallyinterestedindesigninga
routine production plan for consecutive cycles, while the
interactionbetweenadjacentcyclesistakenintoaccount.
163
N Shirvani, R Ruiz, Sh Shadrokh
Regarding these real cases, the cyclic version of the

problemisalsoconsideredinthecurrentresearch.
NONCYCLICSCHEDULES
In this section we consider a short scheduling period
where the manufacturer should schedule jobs between
dummydeadline andthelastdeadline .Atwophase
algorithm has been designed and it is described in the
following.
PHASE1:INITIALSOLUTION
Corresponding to each deadline , We define as the
minimum period of time before that should be
dedicated to process the jobs related to the next
deadlines. iscalculatedbyarecursiveformulaasbelow:
where
max 0, 1
0 and
pj

Di
Di
Once all the are calculated, 0 reveals that

processing all jobs in the available time horizon is
impossibleandextratimeisneeded.Sointhiscasethere
isnofeasiblesolutionfortheproblem.Otherwise,wecan
continue by using Algorithm 1 to generate an initial
solution for the problem. This algorithm, adopts the well
known WSPT rule and revises it for scheduling a single
machine in presence of release dates and deadline
constraints. Algorithm 1 starts from the last deadline
and generates an availability list of the jobs,
including all the unscheduled jobs where
. Then
is considered as the decision time for
scheduling. At each time a candidate list of the available
jobs is updated by considering release date limitations.
The candidate jobs are then sorted in increasing order of
and the job with minimum ratio
, which
has the lowest priority for scheduling close to the
deadline,isselected.Aftersettingthestarttimeofthejob
to , the decision time is increased to the completion
time of the scheduled job ( ). Updating of the
candidate list and the selected job continues until all the
availablejobsarescheduled.Oncetheavailabilitylistisan
empty set, the scheduling of the jobs related to the
previous deadline is started by removing the jobs which
; then decreases
are completely scheduled before
by 1. The removed jobs are added to availability list in
addition to the jobs with
. Then, the whole
procedure is iterated to schedule all the remained jobs.
The internal loop of the algorithm is iterated at most for
times, so the time complexity of the
algorithmcanbeconsideredascubictime
.Ateach
decision time if the candidate list is empty while some
availablejobshavenotbeenscheduledyet,theproblemis
infeasible. The reason can be explained as follows. In
order to minimize the holding cost, our intention is to
schedule all the available jobs as late as possible, before
thedeadline;henceforeachdeadline( ),thealgorithm
startsfromthepoint
inordertoschedule
all the available jobs on the machine without any idle
time. However, an empty candidate list forces the next
available job to be scheduled later, and consequently
resultsinanidletime.Becauseofthisidletime,processing
oftheremainingavailablejobsbefore isimpossibleand
asaresulttheproblemisinfeasible.
PHASE2:IMPROVEDSOLUTION
Algorithm 1 generates a solution for the problem by
determiningthestarttime( )ofeveryjob .Then,a
sequence of the jobs, in increasing order of the start
times,isusedtodemonstratetheoutputofthealgorithm.
Since the algorithm is always adhering to the WSPT rule
unlessthereleasedateanddeadlineconstraintsforceitto
change the job sequence, the output is expected to be a
relatively good one. However, there are still some cases
thatrevealthepotentialforimprovementofthesolution.
Wefirstdiscussonthesecasesbyconsideringthesolution
generated by the algorithm and checking the following
criteria:
There is a deadline , and a job such
and and,
that
For the previous adjacent job of in sequence ,
calledjob ,
Theabovementionedcriteriameansthatthejob should
startlaterincomparisontojob duetotheWSPTrule.So
the possibilities of postponing in sequence should be
checked. This improvement is investigated by asimple
localsearchwhichisnowdetailed.
Incaseforadeadline , thecriteriaarevalid,we
firstdetermineaset

,

which includes the jobs that can be moved backward in

thesequence .Allthecombinationsofthosejobscanbe
considered as the available backward groups. The set of
jobs

,
is also generated,
including the jobs that can be moved forward in the
sequenceandinthesamemannerallthecombinationsof
thesejobsareconsideredasthepossibleforwardgroups.
Once the backward and the forward groups are selected,
allthemembersofbackwardgroupareremovedfromthe
schedule, and the forward jobs are scheduled regarding
theWSPTruleaslateaspossible.Thenallthejobswhich
arecompletelyscheduledbefore areremovedfromthe
scheduleandAlgorithm1isthenappliedtorescheduleall
theunscheduledjobs.Theoriginalsequence isreplaced
by the new sequence , if provides a solution with
betterholdingcost.Thewholeprocedureisiterateduntil
nodeadlinesatisfiesthecriteria.
164
Property1Intheoptimumsolutionofthecyclicproblem,
thereisatleastonedeadline suchthatbyconsideringa
resultsin
.
cycleendstothe , ,
ANILLUSTRATIVEEXAMPLE
Thealgorithmisappliedtosolveanexampleproblemwith
10 and
7. Job specifications are presented in
Table1.Asthefirststep,thevaluesof and mustbe
calculated base on Eq. 1 and Eq. 2. Table 2 shows these
0,wecanuseAlgorithm1,togenerate
values.Since
aninitialsolution.TheGanttchartoftheinitialsolutionis
illustrated in Figure 1. As it is shown all the jobs are
scheduled between dummy deadline
0 and the last
deadline
7. The jobs 7, 8 and 9, With deadline
7areschedulebetween
2 4
1.09
5.09 and
7. Based on the WSPT rule sequence of
these three jobs should be 7, 8, 9 , but since the shelf
life of job 7 is 1, the job is not allowed to be prepared
before time 6, therefore job 7 goes after job 8 in the
solution.Job4thatisrelatedto
4istheonlyjobthat
crosses a deadline (
2). Checking the criteria reveals
that the second criterion is not valid for the job and
therefore no improvement is possible. The presented
solution with the total holding cost 14.94 is the best
solutionfortheexampleproblem.
Proof1Anobviousconditionforfeasibilityoftheproblem
is that summation of all process times should not exceed
thecyclelength.Soineachsolutionthemachineshouldbe
idleforawhile.Inordertominimizethetotalholdingcost,
inoptimumsolutionsjobsarescheduledaslateaspossible
before their deadlines and idle times therefore must be
inserted just after a deadline such as . Based on the
assumptions, corresponding to the idle time started from
thereisnojobsuchthat
and
.
Based on Property 1, 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
thecycle.Inthiscaseitispossibletobreakthecyclefrom
this point and treat it as a limited time horizon problem.
Sotosolvethecyclicproblem,everydeadline , is
independently selected as a break point. After updating
the problem parameters to obtain a cycle started from
zero, the whole procedure presented in Section 3 is
applied to find a candidate solution. Finally, the best
solution is the alternative solution that provides the
minimumholdingcost.
Tab.1Jobspecificationoftheexampleproblem.
j
0
1
2
3
4
5
6
7
8
9
0.84
0.21
0.65
0.72
0.65
0.43
0.36
0.73
0.91
0.27
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
2.38
4.76
6.15
1.39
6.15
6.98
8.33
2.74
3.30
7.41
COMPUTATIONALRESULTS
In the current section, numerical experiments are
conducted for 60 random instances. We consider the
planinghorizonlength tobe7,15andthetotalnumber
of job is supposed to be 15, 20 and 30. Also two level
1/2and2/3ofhorizonlengthareconsideredasnumberof
deadlines . The deadlines are randomly determined in
the time horizon and the jobs are assigned to these
deadlines randomly. The processing times, and the shelf
livesaregeneratedfromuniformdistributions 0,1 and
0, , respectively. For each combination of the
parameterswegenerate5samplessuchthatallinstances
arefeasibleatleastforthecyclicversion.Firstwetestthe
instancesbyconsideringnoncyclicschedules.Allinstances
are successfully solved. In each group there are some
instances which are infeasible.Table 3illustrates average
CPUtimeandthepercentageoffeasibleinstances.
Tab.2Calculationof intheexampleproblem.
0
1
2
3
0
2
4
7
0
1.7
2.16
1.91
*TotalRequiredProcessTimefor
0
0.3
0.16
1.09
0.14
0.16
1.09
0
Tab.3Computationalresultsofnoncyclicproblems.
T
Fig.1TheGanttchartoftheinitialsolutionfortheexample
problem.
3
7
5
CYCLICSCHEDULES
We now consider the same problem in the case that the
manufacturerestablishesalongtermrelationshipwiththe
customers and needs to design aroutine plan for
production cycles. It is supposed that the manufacturer
and the customers are working based on a long term
contractthatobligesthemtosatisfyfixedrepeatedorders
during the cycles. Instead of designing a dedicated
solution for this problem we show that the cyclic version
can be converted to some independent noncyclic
problemsandthealgorithm,depictedinprevioussection,
canbeappliedforsolvingthem.Here,wesupposethatin
thefeasiblesolution ,themachinecannotbeidleattime
,unlessthereisnojob suchthat
and
,
Property1isdirectlyderivedfromthisassumption.
3
15
5
m
15
20
30
15
20
30
15
20
30
15
20
30
CPUtime(ms)
0.00
0.05
0.20
0.05
0.25
0.05
0.20
0.10
0.30
0.20
0.15
0.35
Feasiblity
40%
60%
80%
40%
80%
40%
80%
40%
80%
80%
60%
60%
Next,wecomputationallyevaluatetheperformanceofthe
algorithm presented for the cyclic version with the same
instances. All instances are successfully solved and as it
was expected, all samples have feasible solutions. These
results, in comparison to the previous experiment, reveal
that adopting cyclic schedule might increase the
manufacturers ability to satisfy the customers orders.
Among the 60 instances, 23 have no feasible solutions in
thenoncyclicschedule.Inotherwords,38.3%ofinstances
165
are infeasible in the noncyclic version. Furthermore,

amonginstanceswhicharefeasibleinbothcasesthereare
samplesinwhichthecyclicscheduledecreasestheholding
costupto50%.Inthecurrent
experiments,thesolutionof12instancesimproveincyclic
version,thatmeans20percentsofinstancesareimproved
and average of improvement among these instances is
6.7%.Table4detailstheseresults.
Tab.4Computationalresultsofthecyclicproblems.
T
3
7
5
7
15
10
Improvementovernoncyclic
CPUtime
(ms)
Feasible
Instance
No.
Ave.
15
0.65
100%
0%
0.00%
20
0.50
100%
33%
1.10%
30
0.65
100%
25%
2.90%
15
0.35
100%
0%
0.00%
20
0.55
100%
33%
1.10%
30
0.60
100%
0%
0.00%
15
0.50
100%
25%
2.50%
20
0.95
100%
50%
22.50%
30
1.20
100%
50%
5.00%
15
0.90
100%
50%
20.10%
20
1.10
100%
33%
50.00%
30
1.55
100%
67%
3.90%
[2] K.R. Baker and G.D. Scudder. Sequencing with

earliness and tardiness penalties: a review.
OperationsResearch,38(1):2236,1990.
[3] F.D. Anger, C.Y. Lee, and L.A. MartinVega. Single
machine scheduling with tight windows. Research
Report 8616, Department of Industrial and Systems
Engineering,UniversityofFlorida,1986.
[4] G. Wan and B.P.C. Yen. Tabu search for single
machine scheduling with distinct due windows and
weighted earliness/tardiness penalties. European
Journal of Operational Research, 142(2):271281,
2002.
[5] J.E.CArroyo,R.S.Ottoni,andA.OliveiraPaiva.Multi
objective variable neighborhood search algorithms
forasinglemachineschedulingproblemwithdistinct
due windows. Electronic Notes in Theoretical
ComputerScience,281:519,2011.
[6] Z.L. Chen and C.Y. Lee. Parallel machine scheduling
with a common due window. European Journal of
OperationalResearch,136(3):512527,2002.
[7] G. Mosheiov and A. Sarig. Scheduling identical jobs
and duewindow on uniform machines. European
Journal of Operational Research, 201(3):712719,
2010.
[8] B. Mor and G. Mosheiov. Scheduling a maintenance
activity and duewindow assignment based on
commonflowallowance.InternationalJournalofPro
ductionEconomics,135(1):222230,2012.
[9] Y. Huo, J.Y.T. Leung, and X. Wang. Integrated
production and delivery scheduling with disjoint
windows.DiscreteAppliedMathematics,158(8):921
931,2010.
CONCLUSIONSANDFUTURERESEARCH
Inthispaperwestudiedasinglemachineproblemintwo
casesofnoncyclicandcyclicforms.Thefinishedproducts
have been considered to be highly perishable and the
manufacturer was not allowed to store them for more
than the given shelf lives. 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. A revised WSPT rule was
designed for a single machine scheduling problem with
releasedatesanddeadlines.Thenoncyclicproblemswere
then solved by a twophase algorithm that takes
advantageofagoodinitialsolutiontofindanearoptimum
solutioninefficientway.Ithasbeenalsoverifiedthatthe
cyclic version consists of some independent noncyclic
problems and we can use the same algorithm for solving
them. Computational results revealed efficiency of the
proposed algorithms for solving the instances. These
results showed that cyclic scheduling increases the
flexibility and the manufacturer ability to satisfy the
customers orders and reduced holding cost. Developing
the problem by adding setup time and setup cost, and
replacing deadlines by due dates or due windows can be
consideredinfutureresearch.Inadditionasanextension
we can consider distribution planning beside production
scheduling to coordinate a two stage supply chain of
perishableproducts.
REFERENCES
[1] T.C.E. Cheng and M.C. Gupta. Survey of scheduling
researchinvolvingduedatedeterminationdecisions.
European Journal of Operational Research, 38
(2):156166,1989.
166

TheProceedings
Experimental and Numerical Stress-strain Analysis of Composite

Beams
PetarSmiljanic1AleksandarSedmak2DzindoEmina2EmilVeg3
1
CompanyProblemBelgrade
FacultyofMechanicalEngineering,UniversityofBelgrade
InnovationCenterofFacultyofMechanicalEngineeringBelgrade
2
3
ARTICLEINFO:
Abstract:
Adhesive
Compositebeams
Compositematerials
Bondedjoints
Stressstrain
Astructuralmembercomposedoftwoormoredissimilarmaterialsjoinedtogethertoactasaunit.There
are two main benefits of composite action in structural members. First, by rigidly joining the two parts
together,theresultingsystemisstrongerthanthesumofitsparts.Second,compositeactioncanbetter
utilizethepropertiesofeachconstituentmaterial.Compositesconsistingofresinmatricesreinforcedwith
discontinuous glass fibers and continuous glassfiber mats are widely used in truck and automobile
componentsbearinglightloads.
Citation:SmiljanicP.,etal.:ExperimentalandNumericalStressstrainAnalysisofCompositeBeams,2ndInternationalConferenceManufacturingEngineering&Management2012,(2012),
p.167169,ISBN9788055312163
INTRODUCTION
Material systems are composed of a mixture or
combination of two or more constituents that differ in
formormaterialcompositionandareessentiallyinsoluble
ineachother.Inprinciple,compositescanbeconstructed
of any combination of two or more materials metallic,
organic,orinorganic;buttheconstituentformsaremore
restricted. A number of matrix materials are available,
includingcarbon,ceramics,glasses,metals,andpolymers.
Advanced composites possess enhanced stiffness and
lower density compared to fiberglass and conventional
monolithic materials, [12]. While composite strength is
primarilyafunctionofthereinforcement,theabilityofthe
matrix to support the fibers or particles and to transfer
loadtothereinforcementisequallyimportant,[35].Also,
the matrix frequently dictates service conditions, for
example, the upper temperature limit of the composite.
Composites consisting of resin matrices reinforced with
discontinuousglassfibersandcontinuousglassfibermats
are widely used in truck and automobile components
bearing light loads, such as interior and exterior panels,
pistonsfordieselengines,driveshafts,rotors,brakes,leaf
springs,wheels,andclutchplates.
This material has enabled the development of load
bearing components with structural fasteners, ease of
manufacturing, assembly and reducing weight. The
solution was the use of composite beams wood of poor
quality, thus creating significant advantages over
laminated wood beams, both in price and in ease of
manufacturing, purchasing materials and preparation
time.Themostimportantcharacteristicinthiscaseisthe
rigidityoftheappliedmaterialanditselasticmodulus.
Birchplywood
Epoxy
Fig.1Birchplywoodstripsgluedtofirbyepoxyadhesive.
Fir
Carbonsteel
Fig.2 Fir and carbon steel strips bonded by elastic

polyurethaneglue,SIKAFLEX221.
Materialsusedinthepreparationofcompositebeamsand
theircharacteristicsareveryimportant.Tocreateabeam,
inaccordancewiththebasicideaofthebeamssupporting
thedevelopmentoflowcost,adequatecapacityandalow
degree of complexity of production, the following
materials were used: Low carbon steel in the form of
strips and sheets (cut into strips), St35, shaped by cold
rolling, and fir wood category III. Polyurethane glue
SIKAFLEX 221st was used as adhesive. It is a single
component material which hardens in contact with
moisture from the air. Fir wood beams were cut to size,
figures12.Thecuttingmode,thelengthandarrangement
ofringsandthepresenceofnodes,wasnottakencareof
in the process of choosing the right wood for the
experiment. Testing of adhesives is done 48 hours after
EXPRERIMENTALRESULTS
The experimental part includes the following: composite
woodenbeamsreinforcedwithsteelbands.Twosetswere
done with three identical pieces of different composite
beams:
a)Carbonsteelstripsreinforced,boxedfirbeam.
b)Carbonsteelstripsreinforcedfirsolidbeam.
Geometrical and technological characteristics of
compositebeams:
167
Sikaflex221
P. Smiljanic, et al.
Experimental and Numerical Stress-strain Analysis of Composite Beams
bonding. Testing was performed by simple three point

bending. The applied forces and Flexion were recorded.
ResultsaregiveninTab.1
Tab.1Appliedforcesandmeasuredflexions
Beam
box
Beam
box
Beam
box
Force(N)
Flexion
(mm)
33.35
0.14
284.10
1.04
2700.00
7.13
Fracturecausedbythe
forceonthebeam.
Result
Tab.3Studyresults
Selection Units SumX
SumY
SumZ
Resultant
set
EntireBody N
0.206856 4905.35 0.105957 4905.35
Tab.4FreeBodyForces
Selection Units SumX
SumY
SumZ
Resultant
set
Entire
N
8.77008e 0.0019229 0.000738807 0.00206181
Body
005
NUMERICALANALYSIS
Numerical analysis was performed by the finite element
method.PolyurethaneglueSIKAFLEX221andPlaincarbon
steelpropertiesaregiveninTab.2.
Tab.5FreeBodyMoments
Tab.2Materialproperties
Materialname:
Description:
MaterialModelType:
DefaultFailureCriterion:
PropertyName
Value
Elasticmodulus
3e+6
Poisson'sratio
0.48
Shearmodulus
1.5e+6
Massdensity
1200
Tensilestrength
1e+6
Compressivestrength 1e+6
Yieldstrength
1e+6
Analysisofstressandstrainatthehighestload.
Results of numerical analysis are presented in Tables 35

andFigures37.
Selection Units
SumX
set
Entire
Nm
0
Body
Name
Type
Min
VON:
0.0032756
Stress1 vonMises (MPa)
Stress Node:6810
URES:
Displa Resultant 0mm
cement1 Displace Node:6299
ment
6.92548
ESTRN:
e006
Strain1 Equivalen
Element:
tStrain
646
VON:von 0.003275
Stress2
Mises
(MPa)
Stress Node:6810
SIKAFLEX221
Polyurethane
LinearElasticIsotropic
MaxvonMisesStress
Units
ValueType
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
Materialname:
PlainCarbonSteel
MaterialModelType:
PropertyName
Value
Elasticmodulus
2.1e+11
Poisson'sratio
0.28
Shearmodulus
7.9e+10
Massdensity
7800
Tensilestrength
3.9983e+8
Yieldstrength
2.2059e+8
MaxvonMisesStress
Units
ValueType
N/m^2
Constant
NA
Constant
N/m^2
Constant
kg/m^3
Constant
N/m^2
Constant
N/m^2
Constant
SumY
SumZ
Resultant
1e033
Location
Max
(19.9431mm, 376.31
52.9717mm, (MPa)
110.626mm) Node:266
18.6643
(20mm,25.3
mm
mm,0mm)
Node:
6291
Location
(0.592 mm,
47.69mm,
449.9mm)
(22.26mm,
37.7mm,
449.6mm)
(16.4459mm, 0.430787 (4.929mm,

15.1398mm, Element: 59.27mm,
3.22413mm)
2131 669.86mm)
(19.9431mm, 376.31 (0.592 mm,
52.9717mm, (MPa) 47.69mm,
110.626mm) Node:266 449.9mm)
Materialname:
Fir
MaterialModelType:
PropertyName
Value
Elasticmodulus
1.3e+010
Poisson'sratio
0.39
Shearmodulus
7.9e+010
Massdensity
390
Tensilestrength
7.9e+007
Yieldstrength
4.6e+007
Compressivestrength 4.0e+007
MaxvonMisesStress
Units
ValueType
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.3 F=284N; VonMissesStresses
Materialname:
Birchplzwood(3layer)
MaterialModelType:
LinearElasticOrthotropic
MaxvonMisesStress
PropertyName
Value
Units
ValueType
Elasticmodulus
1.39e+10 N/m^2
Constant
Poisson'sratioxy
0.697
NA
Constant
Poisson'sratioxz
0.42
NA
Constant
Shearmodulus
7.0e+8
N/m^2
Constant
Massdensity
620
kg/m^3
Constant
Tensilestrengthx
1,0e+7
N/m^2
Constant
Tensilestrengthy
1,02279e+8
N/m^2 Constant
Compressivestrengthx 6,7e+6
N/m^2 Constant
Compressivestrengthy 5,63e+7
N/m^2 Constant
Yieldstrength
7.6e+7
N/m^2 Constant
Fig.4 F=284N;VonMissesStressesdetailedview.
168
Experimental and Numerical Stress-strain Analysis of Composite Beams
P.Smiljanic, et al.
DISCUSSION
The results of numerical calculations of load and
deformation of the composite beam were confirmed by
testing the beam samples. In the boxbeam bending,
support distance was 900 mm, and the geometric
characteristics of the beam were exactly the same as in
the numerical model. Deformation was measured in the
middle of the tested beam. That was also the position of
theappliedload.Examinationofthesolidbeamwasdone
inthesameway,withthesamesupportspanof900mm.
In examining the boxbeam there was a fracture at the
bucklingforceof2700Nanddeflectionof7.13mm.Force
values are higher because of greater rigidity of the beam
materials.Fortheforcerangefrom1962Nto4905Nand
the deflection of 5mm13.2mm there was no beam
fracture. The force values, for corresponding deflection,
aredifferentfromthenumericallyobtainedduetohigher
stiffness of the wooden beam materials. In the beam
bending test we were able to determine the mechanical
propertiesofusedmaterials.
Fig.5F=284N;Beamdeformation.
CONCLUSIONS
Fig.6F=284N;Equivalentstrain.
Analyses were performed with at the maximum loaded

beams.Valueoftheforceatwhichthefracturezonewas
created has caused greater deformation than the
calculated one. The reason is beam buckling under the
force, and the assumption that the numerical model of
birch plywood is anisotropic. Examination of the solid
woodenbeamwasdoneinthesameway,withthesame
range. Force values are higher because of higher beam
material modulus. The study confirms the characteristics
ofcalculationcapacity.Increaseofthebeamdeflectionis
proportional to the increase in bending force. The values
for the corresponding deflection of force are different
from the numerically obtained due to higher stiffness of
theusedwoodenbeams.
Wecannoticethatthedistributionsofstressesduetothe
different elasticity modulus are not equal. This is a basic
ideaforusageofcompositebeams.Thisallowsusbeam
calculationthetomaximizepotentialofusedmaterials.
Data were obtained for samples of materials, which may
not fully correspond to those included in testing. Using
low quality wood material as bearer filling, gives
significant advantage in comparison to laminated wood
bearings in terms of price, producing simplicity, material
acquisitionandproductiontime.
REFERENCES
[1] ZdenekP.Baant,Fellow,ASCE,L.Vtek,Compound
Size Effect In Composite Beams With Softening
Connectors. I: Energy Approach, Journal Of
EngineeringMechanicsNovember1999
[2] ChiKinIuInelasticfiniteelementanalysiscomposite
beams on the basis of the plastic hinge approach,
EngineeringStructures(2008)Volume:30
[3] Bob Matthews Applied Stress Analysis Section XI
CompositeMaterials
[4] Hastin,Z.AnalysisofCompositeMaterials,Journalof
AppliedMechanics,Vol.50/481,September1983
[5] DavidL.McDanelsAnalysisofstressstrain,fracture,
andductulybehaviorofaluminiummatrixcomposites
containg discontiunuos silicon carbide reinforce
ment, Metallurgical and Materials Transactions A,
Vol.
16,
No
6,
(1985),
11051115.
Fig.7F=284N;TotalStrainEnergy.
169

TheProceedings
A Fuzzy Based Decision Support Model for Non-traditional

Machining Process Selection
TolgaTemuin1HakanTozan1JanValek2MartaHarnirov3
1
TurkishNavalAcademy,DepartmentofIndustrialEngineering,Tuzla,Istanbul/TURKEY,Email:tolga.temucin@gmail.com;htozan@dho.edu.tr
MiningandGeologicalFaculty,InstituteofPhysics,VBTechnicalUniversityofOstrava,CzechRepublic,Email:jan.valicek@vsb.cz
NanotechnologyCentre,VBTechnicalUniversityofOstrava,CzechRepublic,Email:marta.harnicarova@vsb.cz
ARTICLEINFO:
Received:21February2011/Revised:24October2011/Accepted:24October2011
Abstract:
Multicriteriadecisionmaking
Fuzzylogic
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, nuclear reactors, automobiles, and etc. Such developments in the field of
material science points out them as indispensable processes due to some benefits such as economic cutting speed,
production of complex shapes. In this respect; 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,
quality of surface finished, environmental impact, time of process, and etc. 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.
The required data for decision matrixes is obtained via a questionnaire to specialists as well as deep discussions
with experts, and making use of past studies. An application of the proposed model is also performed to show the
applicability of the model.
Citation:T.Temuinetal.: AFuzzyBasedDecisionSupportModelforNontraditionalMachiningProcessSelection,2ndInternationalConferenceManufacturingEngineering&
INTRODUCTION
methodstobewidelyused[47].Thepurposeinthisstudy
is to propose a decision support model which is used to
select the best nontraditional machining process option
forcuttingoperationsofaspecificmaterial.Criterionsfor
the proposed model and weights that represent the rate
of importance for those criterions were identified via
questionnaires to specialists, deep discussions with
experts,andmakinguseofpaststudies.Theremainderof
this study is structured as follows. In the second section
research methods are introduced briefly. In the third
section firstly the proposed decision support model is
introduced and then a case study is performed. Finally,
conclusionsandfurtherrecommendationsarehighlighted
inthelastsection.
ThewellknownphilosophicalstatementdenotedbyRen
Descartes I think, therefore I exist is perhaps the best
comment that discloses the importance of thinking in
human life. Humans used this vital ability in decision
makingprocesswhichcanbedefinedastheprocedureto
findthebestalternativeamongasetoffeasibleones[1].
However; complexity of decision making processes
changed in the course of time proportional to the
improvements in science. Consequently, decision making
process wouldnt be easy as formerly because of the
increased number of inputs such as conflicting criterions,
importanceweights,andetc.Accordingtotheconceptof
restricted rationalism, it is claimed that the capacity of
human is limited in the solution of complex problems.
Thus,evolutionofMCDMmethodshasstarted.Theyhelp
toimprovethequalityofdecisionsbymakingtheprocess
more explicit, rational, and efficient. These methods are
powerful tools which are widely used for complex
problems featuring high uncertainty, conflicting
objectives, multi interests, and perspectives [2]. MCDM
hasbeenoneofthefastestgrowingproblemareasduring
at least the last two decades [3]. Advances in industries
like nuclear reactors, automobiles, missiles, and turbines
require high strength and temperature resistant alloys.
This forced scientists in the field of material science to
develophigherstrengthmaterials.Howeverinthecourse
of time traditional machining processes wouldnt be
sufficienttoproducecomplexshapesinthestrengthened
materials such as titanium and stainless steel.
Consequently,proportionaltotheincreaseinthestrength
ofworkmaterial,cuttingtoolmaterialsalsorequiredtobe
harder which caused the evolution of NTM processes.
NTM processes are characterized by the presence of a
large number of viable alternatives, uncertainties
concerning the process capabilities, and shortage of the
experiencedplanners[4].Inthiscontext,theillstructured
and multi criteria nature of NTM process selection
problems involving many uncertainties concluded MCDM
ResearchMethods:TOPSISandFuzzyTOPSIS
Asadecisionsupporttool,TechniqueforOrderPreference
bySimilaritytoIdealSolution(TOPSIS)isusedbothincrisp
and fuzzy environments. In this section, TOPSIS, fuzzy set
theory,andFuzzyTOPSISmethodsareexplainedbriefly.
TOPSIS
The first method used in this study is TOPSIS which is
developed by Yoon and Hwang in 1980. This method is
employedfor[811]:
Computationprocedureissimple;
Methodslogicisunderstandable;and
Importance weights are incorporated into the
procedure.
Ideal Solution is the choice with best performances in
everycriterionwhichisindeedimpossibletocometrue.In
thiscase,thechoicenearesttotheidealsolutionmustbe
preferred.ThemethodusestheconceptsofPositiveIdeal
SolutionandNegativeIdealSolutiontodeterminethebest
choice. The positive ideal solution is one maximizing the
benefitcriterionandminimizingthecostonewhileforthe
negativeidealsolutiontheoppositeistrue[8].According
to this method the best alternative is the one which is
170
A Fuzzy Based Decision Support Model for Non-traditional Machining Process Selection
nearest to the positive ideal solution and farthest to the

negativeidealsolution[12].Thealgorithmofthismethod
isdescribedasfollows:
Step1:ConstructDecision()andWeight()Matrixes:
Thedecisionmatrix,Aconsistingthreecomponentshasto
bedetermined.Thesecomponentsareviablealternatives
T. Temuin, et al.
Step7:CalculateRelativeClosenesstotheIdealSolution:
Therelativeclosenesstotheidealsolution, C i* ,foreach
alternativecanbecalculatedwithEq.(7).
Ci*
definedby a1 , a 2 ,, ai , ak ,, am ;criterionsdefined
c1 , c2 ,, c j ,, cn
by
alternatives with respect to each criterion defined by

a ij i 1, 2,..., m j 1, 2,..., n . In this step the
Step 8: Rank Preference Order: The alternative with the

highest C i* isthebestchoice.
w1 ,
FuzzysetstheoryinMCDM
w2 ,, w j ,, wn foreachcriterionsatisfying w j 1
j 1
a11 a1n
A
a
m1 amn
Fuzzylogic(FL)notionwasfirstintroducedbyL.A.Zadehin
1965.Itisapreciselogicof imprecisionandapproximate
reasoning [13]. It provides a simple way to arrive at a
definite conclusion based upon vague, ambiguous,
imprecise, noisy, or missing input information [14]. On
thecontrarytomanycasesthatinvolveshumanjudgment,
crispsetsdividethegivenuniverseofdiscourseintobasic
two groups; members, which are certainly belonging the
set and nonmembers, which certainly are not. This
delimitation which arises from their mutually exclusive
structure enforces the decision maker to set a clearcut
boundarybetweenthedecisionvariablesandalternatives.
The basic difference of FL is its capability of data
processing using partial set membership functions [15].
VeryofteninMCDMproblemsdataisimpreciseandfuzzy
[3].Onthecontraryofcrispsettheory,fuzzysettheoryis
developedtocopewiththesekindsofindefiniteness.
isalsoneedtobeconstituted.
Step2:ConvertCriterionstotheSameType:Conversion
is done by dividing 1 with the evaluation values in the
columnofcriterionwhichisdesiredtobeconverted.
Step 3: Construct Normalized Decision Matrix (): The
normalizeddecisionmatrixcanbeconstructedwithEq.(1)
tomakethedatadimensionless.
xij
aij
FuzzyTOPSIS
(1)
PrincipalstepsoffuzzyTOPSISmethodcanbedescribedas
follows:
2
kj
k 1
(7)
where 0 C i* 1 and i 1, 2, 3, ..., m .
and the performances of
weight matrix, W , having the weights defined by
Si
Si Si*
Step1:ConstructDecision()andWeight()Matrixes
Step 4: Construct Weighted Normalized Decision Matrix
(): The weighted normalized decision matrix can be
constructedwithEq.(2).
Step2:ConvertCriterionstotheSameType
Step5:DeterminePositiveandNegativeIdealSolutions:
) and Weight (
)
Step 3: Construct Fuzzy Decision (
Matrixes: Criterions can be grouped as objective and
subjective ones [16]. Error rate defined for decision and
weightmatrixeshelpstoobtainatriangularfuzzynumber
(TFN)foreachcrispnumber.ConsideringaTFNformedby
If c1 and c2 arebenefitandcostcriterionsrespectively,
a triplet
positive and negative ideal solutions can be determined

withEqs.(3)and(4).
andthemiddleonecanbecomputedwithEq.(8).
y ij xij * w j
(2)
max p ,J c ;m inp ,J c
m inp ,J c ; max p ,J c
ij
ij
ij
ij
(3)
(4)
Si
(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.
Equalize the highest value of a3 ' s in that
*
columnto x .
171
):
Step 4: Construct Normalized Fuzzy Decision Matrix (
Normalizedfuzzydecisionmatrixisconstructedasfollows:
Forbenefitcriterions:
j 1
y *j ) 2
error rate
a3 crisp data crisp data *
100
respectively,canbecalculatedwithEqs.(5)and(6).
Si*
error rate
a1 = crisp data crisp data *
100
a2 (crisp data)
(8)
Step 6: Calculate Separation Measures: The positive and

negative ideal separation measures,
a a , a , a , the most extreme values
Thenormalizedvalueof a a1 , a2 , a3 .
* * *
Forcostcriterions:
T. Temuin, et al.
are benefit criterions where higher values are desired;

while OC, IC, TSU, DTE, W, SR, V, N, AP, and R are cost
criterionswherelowervaluesarealwayspreferred.
Determine the smallest value of a1 ' s in that

column.
Equalize the smallest value of a1 ' s in that
*
columnto x .
x* x* x*
, , .
a3 a2 a1
Thenormalizedvalueof a
Step 5: Construct Weighted Normalized Fuzzy Decision

)
Matrix
(
Each
fuzzy
evaluation
value,
aij i 1, 2,3,..., m j 1, 2,3,..., n , has to be multiplied
with fuzzy weight,
w j 1, 2,3,..., n ,
j
to obtain
weightednormalizedfuzzydecisionmatrix.
Step 6: Determine Fuzzy Positive and Fuzzy Negative
Ideal Solution Sets: Fuzzy positive ideal reference point
FPIRP, A and fuzzy negative ideal reference point
FNIRP, A aredefinedwithEqs.(9)and(10).
A v1 , v2 ,..., vn
(9)
A v , v ,..., v
(10)
where v j 1,1,1 and v j 0,0,0 , j 1, 2,..., n.
Fig.1Structureofthemachiningprocessselectiondecision
supportmodel
Step 7: Calculate Separation Measures: Vertex method

can be used to compute the distance between fuzzy
m1 , m2 , m3
Acasestudyformachiningprocessselection
AISI309stainlesssteelisconsideredduringtheevaluation
phase of each alternative machining process in terms of
criterions.AISI309isaheatresistantalloywithoxidation
resistance to 19000F. The high chromium and relatively
low nickel content of it provide good resistance to high
temperature sulphur bearing atmosphere. Some features
of this stainless steel are moderate strength at high
temperature, ease of fabrication, and good weldability.
The chemical composition of AISI 309 is given in Table 1
[20].
are two TFNs then the distance between them is

calculatedwithEq.(11).
1
2
2
2
n1 m1 n2 m2 n3 m3
3
(11)
Step8:CalculateRelativeClosenesstotheIdealSolution
Step9:RankPreferenceOrder
Tab.1ChemicalcompositionofAISI309(%)[20]
ProposedDecisionSupportModelandaCaseStudy
forMachiningProcessSelection
Proposeddecisionsupportmodel
Oxyfuel, laser, and plasma machining processes are the
most common ones [18]. Additionally, water jet and
abrasive water jet are the most rapidly improving
technological methods of machining materials [19].
Therefore, in this study concern is focused on these five
machining process alternatives. Determination of the
criteriafortheproposeddecisionsupportmodelwasdone
via questionnaires filled in by specialists as well as deep
discussions with experts studying in Faculty of
ManufacturingTechnologiesofTheTechnicalUniversityof
Kosice, and making use of the past studies [4,6]. Surface
finish,cost,safey,toxicityaresomecriterionsthatshould
beusedinthecomparisonofsomedistinctnontraditional
machiningtechnologies[4,6].Fig.1illustratestheskeleton
of the proposed model including criterions and
alternatives.
Among these criterions, DTE (mm), SR (m), and CS
(m/min) are objective criterions that have absolute
numericalvalues;whileOC,IC,TSU,W,V,N,AP,R,S,HH,
SO,ESCAS,PC,andUFaresubjectivecriterionswhichare
evaluatedonascaleof110byspecialistsandexpertsof
this field. Additionally; S, HH, CS, SO, ESCAS, PC, and UF
MIN
MAX
22.00
24.00
12.00
15.00
0.20
0.045
0.030
2.00
1.00
Determination of the weights concerning each criterion,

error rate (10%), and performances of alternatives in
termsofeachcriterionwasdoneviaaquestionnairefilled
in by specialists as well as deep discussions with experts
studying in Faculty of Manufacturing Technologies of The
Technical University of Kosice. The developed decision
matrixisillustratedinTable2.
Tab.2Decisionmatrix
172
Silicon

d n ,m
Manganese
numbers[17].If n n1 , n2 , n3 and m
Sulphur
Phosphorus
Carbon
Nickel
Chromium
T. Temuin, et al.
to the ideal solution for each alternative shown in Table

10.
MachiningProcessSelectionwithTOPSIS:Costcriterions
in the decision matrix shown in Table 2 are converted to
benefit criterions. The reconstructed decision matrix is
presentedinTable3.DeterminedweightsshowninTable
2 are normalized and presented in Table 4 within the
normalized decision matrix which is constructed via Eq.
(1). The weighted normalized decision matrix shown in
Table5isconstructedviaEq.(2).Equations(5),(6)and(7)
are used to determine positive ideal solution, negative
idealsolution,andrelativeclosenessstotheidealsolution
foreachalternativeshowninTable6.
The
MachiningProcessSelectionwithFuzzyTOPSIS:
decision matrix shown in Table 2 and the weight matrix
showninTable4(lastrowofthetable)arefuzzifiedviaEq.
(8).Thefuzzydecisionmatrixandfuzzyweightmatrixare
presentedinTable7.Thefuzzynormalizeddecisionmatrix
and the fuzzy weighted normalized decision matrix are
presented in Table 8 and Table 9, respectively. Finally,
Equations(11)and(7)areusedtodeterminepositiveideal
solution, negative ideal solution, and relative closenesss
CONCLUSION
In this study, a comprehensive decision support model is
proposedtoassistdecisionmakersintheselectionofthe
right machining process for a specific material. A case
studyisalsoperformed.Therequireddataforthestudyis
obtained via questionnaires given to experts and making
use of past studies. The results reached by TOPSIS and
fuzzy TOPSIS methods showed that WJM is found to be
thebestalternativewhileAWJMisthesecondandLBMis
thethirdalternativesintherankorder.Ontheotherhand;
PAM and OxyFuel Machining seem to be on the fourth
and sometimes on the fifth rank in the sequence
dependingonthechosenmethodforapplication.Further
researches can be performed using other fuzzy MCDM
methodssuchasfuzzyELECTRE,fuzzyPROMETHEEorthe
ones which take into consideration the influences
betweenalternativesandcriterionssuchasfuzzyAnalytic
NetworkProcess(FANP).
Tab.3ReconstructedDecisionmatrix
HH
CS
SO ESCAS PC
UF
LBM
0.375
WJM
1.500
OC
IC
DTE
SR
0.143 0.200 0.125
1.667
0.250
0.333 0.500 0.333
10
TSU
AP
0.333 0.500 0.143 0.143
0.333 0.154 0.250 0.125 0.250
0.250
0.250 0.167 0.500
WJM
0.050
10
0.500
0.500
10
PAM
0.500 0.500 0.250
0.143 0.003 0.167 0.111 0.111 0.167
OFUEL 5
0.200 0.250 0.200
0.200
0.111 0.002 0.250 0.143 0.167 0.250
ESCAS
PC
Tab.4NormalizedDecisionmatrix
HH
CS
SO
UF
OC
IC
TSU
DTE
SR
AP
LBM
0.302 0.318 0.070 0.467 0.466 0.474 0.189 0.174 0.158 0.181 1.2*10 0.482 0.970 0.583 0.876 0.234 0.098
AWJM
0.503 0.557 0.282 0.467 0.466 0.474 0.283 0.407 0.395 0.482
0.707
0.643 0.019 0.438 0.219 0.409 0.688
WJM
0.603 0.636 0.009 0.467 0.466 0.527 0.661 0.610 0.790 0.722
0.707
0.482 0.242 0.438 0.292 0.819 0.688
PAM
0.201 0.159 0.938 0.415 0.466 0.369 0.094 0.610 0.395 0.361 1.4*10 0.276 4*10 0.292 0.195 0.182 0.115
OFUEL
0.503 0.398 0.188 0.415 0.362 0.369 0.661 0.244 0.197 0.289
1*10
0.214 2*10
WEIGHTS 0.065 0.065 0.065 0.065 0.052 0.052 0.065 0.065 0.052 0.045
0.065
0.065 0.065 0.052 0.052 0.058 0.058
DTE
SR
0.438 0.250 0.273 0.172
Tab.5WeightedNormalizedDecisionmatrix
HH
CS
SO
ESCAS
PC
UF
OC
IC
TSU
AP
LBM
0.019 0.021 0.005 0.030 0.024 0.024 0.012 0.011 0.008 0.008
0.031
0.063
0.030 0.045 0.014 0.006
AWJM
0.032 0.036 0.018 0.030 0.024 0.024 0.018 0.026 0.020 0.022 0.046 0.041
0.001
0.023 0.011 0.024 0.040
0.016
0.023 0.015 0.048 0.040
WJM
0.039 0.041 6*10
PAM
10
0.030 0.024 0.027 0.043 0.039 0.041 0.033 0.046 0.031
0.013 0.010 0.061 0.027 0.024 0.019 0.006 0.039 0.020 0.016
OFUEL 0.032 0.026 0.012 0.027 0.019 0.019 0.043 0.016 0.010 0.013
10
0.018 2.6*10 0.015 0.010 0.011 0.007
0.014 1.6*10 0.023 0.013 0.016 0.010
Tab.6PositiveandNegativeIdealSolutions,RelativeClosenessstotheIdealSolutionandPreferenceOrders
PositiveIdeal
Solution
NegativeIdeal
Solution
RelativeClosenessstotheIdeal
Solution
PreferenceOrders
LBM
0.109
0.077
0.415
AWJM
0.093
0.080
0.461
WJM
0.083
0.104
0.556
PAM
0.119
0.068
0.364
OXYFUEL
0.120
0.047
0.283
173
T. Temuin, et al.
Tab.7FuzzyDecisionMatrixandFuzzyWeightMatrix
CRI./ALT.
S
H
CS
SO
ESCAS
PC
UF
OC
IC
TSU
DTE
W
SR
V
N
AP
R
LBM
AWJM
WJM
PAM
OXYFUEL
WEIGHTS
(2.700;3.000;3.300)
(3.600;4.000;4.400)
(0.338;0.375;0.413)
(8.100;9.000;9.900)
(8.100;9.000;9.900)
(8.100;9.000;9.900)
(1.800;2.000;2.200)
(0.129;0.143;0.157)
(0.180;0.200;0.220)
(0.113;0.125;0.138)
(1.500;1.667;1.833)
(0.225;0.250;0.275)
(7.200;8.000;8.800)
(0.299;0.333;0.367)
(0.450;0.500;0.550)
(0.129;0.143;0.157)
(0.129;0.143;0.157)
(4.500;5.000;5.500)
(6.300;7.000;7.700)
(1.350;1.500;1.650)
(8.100;9.000;9.900)
(8.100;9.000;9.900)
(8.100;9.000;9.900)
(2.700;3.000;3.300)
(0.299;0.333;0.367)
(0.450;0.500;0.550)
(0.299;0.333;0.367)
(9*104;105;11*104)
(0,299;0.333;0.367)
(0.138;0.154;0.169)
(0.225;0.250;0.275)
(0.113;0.125;0.138)
(0.225;0.250;0.275)
(0.900;1.000;1.100)
(5.400;6.000;6.600)
(7.200;8.000;8.800)
(0.045;0.050;0.055)
(8.100;9.000;9.900)
(8.100;9.000;9.900)
(9.000;10.00;11.00)
(6.300;7.000;7.700)
(0.450;0.500;0.550)
(0.900;1.000;1.100)
(0.450;0.500;0.550)
(9*104;105;11*104)
(0.225;0.250;0.275)
(1.800;2.000;2.200)
(0.225;0.250;0.275)
(0.150;0.167;0.183)
(0.450;0.500;0.550)
(0.900;1.000;1.100)
(1.800;2.000;2.200)
(1.800;2.000;2.200)
(4.500;5.000;5.500)
(7.200;8.000;8.800)
(8.100;9.000;9.900)
(6.300;7.000;7.700)
(0.900;1.000;1.100)
(0.450;0.500;0.550)
(0.450;0.500;0.550)
(0.225;0.250;0.275)
(1.800;2.000;2.200)
(0.129;0.143;0.157)
(0.003;0.003;0.003)
(0.150;0.167;0.183)
(0.099;0.111;0.122)
(0.099;0.111;0.122)
(0.150;0.167;0.183)
(4.500;5.000;5.500)
(4.500;5.000;5.500)
(0.900;1.000;1.100)
(7.200;8.000;8.800)
(6.300;7.000;7.700)
(6.300;7.000;7.700)
(6.300;7.000;7.700)
(0.180;0.200;0.220)
(0.225;0.250;0.275)
(0.180;0.200;0.220)
(0.180;0.200;0.220)
(0.099;0.111;0.122)
(0.002;0.002;0.002)
(0.225;0.250;0.275)
(0.129;0.143;0.157)
(0.150;0.167;0.183)
(0.225;0.250;0.275)
(0.058;0.065;0.071)
(0.058;0.065;0.071)
(0.058;0.065;0.071)
(0.058;0.065;0.071)
(0.046;0.052;0.057)
(0.046;0.052;0.057)
(0.058;0.065;0.071)
(0.058;0.065;0.071)
(0.046;0.052;0.057)
(0.041;0.045;0.050)
(0.058;0.065;0.071)
(0.058;0.065;0.071)
(0.058;0.065;0.071)
(0.046;0.052;0.057)
(0.046;0.052;0.057)
(0.052;0.058;0.064)
(0.052;0.058;0.064)
Tab.8FuzzyNormalizedDecisionMatrix
CRI./ALT.
S
HH
CS
SO
ESCAS
PC
UF
OC
IC
TSU
DTE
W
SR
V
N
AP
R
LBM
(0.409;0.455;0.500)
(0.409;0.455;0.500)
(0.061;0.068;0.075)
(0.818;0.909;1.000)
(0.818;0.909;1.000)
(0.736;0.818;0.900)
(0.234;0.260;0.286)
(0.234;0.260;0.286)
(0.164;0.182;0.200)
(0.205;0.227;0.250)
(14*106;15*106;17*106)
(0.614;0.682;0.750)
(0.818;0.909;1.000)
(0.818;0.909;1.000)
(0.818;0.909;1.000)
(0.234;0.260;0.286)
(0.117;0.130;0.143)
AWJM
(0.682;0.758;0.833)
(0.716;0.795;0.875)
(0.245;0.273;0.300)
(0.818;0.909;1.000)
(0.818;0.909;1.000)
(0.736;0.818;0.900)
(0.351;0.390;0.429)
(0.545;0.606;0.667)
(0.409;0.455;0.500)
(0.545;0.606;0.667)
(0.818;0.909;1.000)
(0.818;0.909;1.000)
(0.016;0.017;0.019)
(0.614;0.682;0.750)
(0.205;0.227;0.250)
(0.409;0.455;0.500)
(0.818;0.909;1.000)
WJM
(0.818;0.909;1.000)
(0.818;0.909;1.000)
(0.008;0.009;0.010)
(0.818;0.909;1.000)
(0.818;0.909;1.000)
(0.818;0.909;1.000)
(0.818;0.909;1.000)
(0.818;0.909;1.000)
(0.818;0.909;1.000)
(0.818;0.909;1.000)
(0.818;0.909;1.000)
(0.614;0.682;0.750)
(0.205;0.227;0.250)
(0.614;0.682;0.750)
(0.273;0.303;0.333)
(0.818;0.909;1.000)
(0.818;0.909;1.000)
PAM
(0.273;0.303;0.333)
(0.205;0.227;0.250)
(0.818;0.909;1.000)
(0.727;0.808;0.889)
(0.818;0.909;1.000)
(0.573;0.636;0.700)
(0.117;0.130;0.143)
(0.818;0.909;1.000)
(0.409;0.455;0.500)
(0.409;0.455;0.500)
(2*105;2*105;2*105)
(0.351;0.390;0.429)
(0.0003;0.0004;0.0004)
(0.409;0.455;0.500)
(0.182;0.202;0.222)
(0.182;0.202;0.222)
(0.136;0.152;0.167)
OXYFUEL
(0.682;0.758;0.833)
(0.511;0.568;0.625)
(0.164;0.182;0.200)
(0.727;0.808;0.889)
(0.636;0.707;0.778)
(0.573;0.636;0.700)
(0.818;0.909;1.000)
(0.327;0.364;0.400)
(0.205;0.227;0.250)
(0.327;0.364;0.400)
(16*107;18*107;2*106)
(0.273;0.303;0.333)
(0.0002;0.0002;0.0003)
(0.614;0.682;0.750)
(0.234;0.260;0.286)
(0.273;0.303;0.333)
(0.205;0.227;0.250)
Tab.9FuzzyWeightedNormalizedDecisionMatrix
CRI./ALT.
LBM
S
(0.024;0.029;0.035)
HH
(0.024;0.029;0.035)
CS
(0.004;0.004;0.005)
SO
(0.048;0.059;0.071)
ESCAS
(0.038;0.047;0.057)
PC
(0.034;0.042;0.051)
UF
(0.014;0.017;0.020)
OC
(0.014;0.017;0.020)
IC
(0.008;0.009;0.011)
TSU
(0.008;0.010;0.012)
DTE
(8*106;1*106;12*107)
W
(0.036;0.044;0.053)
SR
(0.048;0.059;0.071)
V
(0.038;0.047;0.057)
N
(0.038;0.047;0.057)
AP
(0.012;0.015;0.018)
R
(0.006;0.008;0.009)
AWJM
WJM
(0.040;0.049;0.059)
(0.048;0.059;0.071)
(0.042;0.051;0.062)
(0.048;0.059;0.071)
(0.014;0.018;0.021) (0.00048;0.00059;0.00071)
(0.048;0.059;0.071)
(0.048;0.059;0.071)
(0.038;0.047;0.057)
(0.038;0.047;0.057)
(0.034;0.042;0.051)
(0.038;0.047;0.057)
(0.020;0.025;0.030)
(0.048;0.059;0.071)
(0.032;0.039;0.047)
(0.048;0.059;0.071)
(0.019;0.023;0.028)
(0.038;0.047;0.057)
(0.033;0.041;0.050)
(0.022;0.027;0.033)
(0.048;0.059;0.071)
(0.048;0.059;0.071)
(0.048;0.059;0.071)
(0.036;0.044;0.053)
(0.0009;0.0011;0.0014)
(0.012;0.015;0.018)
(0.029;0.035;0.043)
(0.029;0.035;0.043)
(0.009;0.012;0.014)
(0.013;0.016;0.019)
(0.021;0.026;0.032)
(0.043;0.053;0.064)
(0.043;0.053;0.064)
(0.043;0.053;0.064)
PAM
(0.016;0.020;0.024)
(0.012;0.015;0.018)
(0.048;0.059;0.071)
(0.042;0.052;0.063)
(0.038;0.047;0.057)
(0.027;0.033;0.040)
(0.007;0.008;0.010)
(0.048;0.059;0.071)
(0.019;0.023;0.028)
(0.017;0.021;0.025)
(1*105;12*107;14*107)
(0.020;0.025;0.030)
(2*105;24*106;3*105)
(0.019;0.023;0.028)
(0.008;0.010;0.013)
(0.010;0.012;0.014)
(0.007;0.009;0.011)
OXYFUEL
(0.040;0.049;0.059)
(0.030;0.037;0.044)
(0.010;0.012;0.014)
(0.042;0.052;0.063)
(0.030;0.036;0.044)
(0.027;0.033;0.040)
(0.048;0.059;0.071)
(0.019;0.023;0.028)
(0.010;0.012;0.014)
(0.013;0.016;0.020)
(1*106;12*107;14*107)
(0.016;0.020;0.024)
(12*106;15*106;18*106)
(0.029;0.035;0.043)
(0.011;0.013;0.016)
(0.014;0.018;0.021)
(0.011;0.013;0.016)
Tab.10PositiveandNegativeIdealSolutions,RelativeClosenessstotheIdealSolutionandPreferenceOrders
PositiveIdeal
Solution
NegativeIdeal
Solution
RelativeClosenessstotheIdeal
Solution
PreferenceOrders
LBM
16.514
0.493
0.029
AWJM
16.371
0.638
0.037
WJM
16.246
0.764
0.045
PAM
16.582
0.424
0.025
OXYFUEL
16.569
0.436
0.026
Acknowledgements
funded by Structural Funds of the European Union and

state budget of the Czech Republic and the project
RMTVCNo.CZ.1.05/2.1.00/01.0040
This research has been elaborated in the framework of

theIT4InnovationsCentreofExcellenceproject,reg.no.
CZ.1.05/1.1.00/02.0070 supported by Operational
Programme'ResearchandDevelopmentforInnovations'
174
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TheProceedings
Calculation Fire and Explosion Index Value for the Biogas Station
PetrTrvnek1PetrJunga1TomVtz1
1
MendelUniversityinBrno,DepartmentofAgriculture,FoodandEnvironmentalEngineering,Zemdlsk1,61300Brno,Email
ARTICLEINFO:
Category:ProfessionalPaper
Abstract:
Biogasstorage
FireandExplosionIndex
Hazards
Processsafety
Biogasstationsandtheirgasstoragesarepotentialsourcesofthefireandexplosionrisk.Theseriskswere
overlooked to date. The quantity of biogas stations grow up in the Czech Republic. For this reason the
numbersofrisksgrowup,too.Thereforeisanimportantevaluationoftheriskforthesesourcesaccording
tothechosenmethod.OneofthemethodsisDowsFireandExplosionIndex.Itisinternationallyaccepted
method developed by Dows Chemical Company for identification of fire and explosion of process units.
DowsFireandExplosionIndexevaluatesonlyexplosiveandflammablesubstances.Thismethodareused
fordetectofpointswiththegreatestofpotentiallossesandenabletopredicttheextentofthedamage.
Citation:TrvniekP,JugaP,VtzT.CalculationFireandExplosionIndexValuefortheBiogasStation,2ndInternationalConferenceManufacturingEngineering&Management2012,
(2012),p.176177,ISBN9788055312163
INTRODUCTION
the landfill were not calculated). Biogas is composed
mainlyfromtwomajoritygases,CH4andCO2.Contentof
CH4 is approximately 50 % and content of CO2 is also 50
%.Therateofgasesfluctuatesinthedependencyonkind
of processing material and technology which is used.
ThereisrelativelybigamountofriskintheCzechRepublic,
which was not devoted big attention to this date. Biogas
stationshavehadseveralaccidentsintheCzechRepublic.
Forexample,theresidualbiogasignitedduringadjustment
of gas tank on the May in the year 2009. The result was
burnedworker,whosexecutedtheadjustment.Thenext
case is leakage of biogas in biogas station in r nad
Szavou on the May 2011. Biogas probably contained
mainly CO2, so three employes were intoxicated by this
gas. Unfortunately accidents were more serious in the
Germany. The biogas production facility exploded in the
municipality Oggenried on the November 2007 and the
building was damaged. The next explosion of equipment
was on December 2007 in the municipality Daugendorf.
Therethebiogasreactorwasdamaged[5].
Index methods belong to generic methods of risk

identification.Thesemethodshelptodetectspecificrisks,
which were gradually developed for identification on the
baseofexperience.Differentriskcannotbedetectedwith
theseindexmethods.Thesemethodsarenotequippedto.
ThetypicalrepresentativeofindexmethodsisDowsFire
andExplosionIndexmethod[1].ThefirsteditionofDows
Fire&ExplosionIndex(F&EI)arisesintheyear1964.The
methodprimaryservesasleadforaselectionofsuccessful
wayoffireprotection.Thenextaimwastoobtainmethod
for relative evaluation of processing units, which are
targeted to key point of equipment. The purpose of the
F&EIsystemis[4].
1. Quantify the expected damage of potential fire,
explosionandreactivityincidentsinrealisticterms.
2. Identifyequipmentthatwouldbelikelytocontribute
tothecreationorescalationofanincident.
3. CommunicatetheF&EIriskpotentialtomanagement.
TheF&EIusesalmost50year.Duringthistimethemethod
wasappliedinmanyindustriesandactivities,whichrelate
withthis.Itisaboveallchemicalindustry.Butthehighfire
andexplosionpotentialhaveforexampleequipmentsfor
storingorcarbonhydrogenprocessing[6].Nontraditional
applicationofthismethodcanbeforexampleintegration
ofF&EItotheprocessdesignandoptimizationofchemical
deviceswithrespecttosafety[7].Whenitcomesfulfilling
ofthispotentialsoitleadstolossoflife,seriousinjuries,
huge financial losses due to equipment damage and
production interruption, job losses to the workers and
permanentdamagetotheenvironment[2].Thispotential
can have also biogas stations. Currently 327 biogas
stations with installed output in the range from 50 kW
(municipalityZavidov,districtRakovnk)to2000kW(Velk
Karlov, district Znojmo) is in the Czech Republic to the
date15.2.2012.Theinstalledpowerofallbiogasstations
is 224.17 MW. Where together 96 biogas stations are
located in the waste water treatment plant and 53 is
locatedintheclosedlandfillof municipalwaste.Therest
of biogas stations are located above all on farms and in
the lesser extent in the industry [3]. When is calculated
that power 0.5 MW of an cogeneration unit get
approximately 800 m3 of buffer volume gas tank so
maximal volume of biogas is approximately 300 000 m3,
which is located in the Czech Republic (biogas station on
Fig.1Consequencesoftheexplosionofbiogasreactorin
themunicipalityDaugendorf[5]
The F&E Index can be one of tools for risk evaluating of
biogas station, similar to other types of analogous
equipments(forexamplestoragetankformethane).
METHODS
Thefivemodelexamplesofbiogasstationswereassigned
for purpose of this paper. Membrane gasholders were
176
Calculation Fire and Explosion Index Value for the Biogas Station
P. Trvnek et al.
placed on these biogas stations. Buffer volume of these

gasholders was 1000 m3 (gasholder No. I), 2000 m3
(gasholder No. II), 3000 m3 (gasholder No. III), 4000 m3
(gasholder No. IV) and 5000 m3 (gasholder No. IV). The
reactor was designed as a cylindrical aboveground tank.
Therooftopofareactorwasmadefromtextilewithalight
support structure on the central pole. This central pole
wassimultaneouslyusedasguidingduringthemovement
gasholder membrane. In the model biogas station was
producedbiogas,whichhashadfollowingparameters:
CH4content
=62%
=37,9%
CO2content
N2content
=0,1%
Calorificvalue =22MJm3
ForevaluatingofF&EIwasusedmethodwhichisshowed
inthedocumentationDowsFire&ExplosionIndexHazard
ClassificationGuide,7thEdition,January1994.
determination is R2 = 0.989. This is demonstrable value

from the statistical view of point. With use of
mathematical function can be determined how large will
be area of exposure in the case of various size storage
tanksaccident.
Fig. 2 Dependency volume of a storage tank on area of

exposure
770
Area of Exposure [m 2]
750
NumberofStorage
II
III
IV
1.GeneralProcessHazard
Basefactor
1.00
1.00
1.00
1.00
1.00
0.65
0.65
0.65
0.65
0.65
GeneralProcessHazardFactor(F1) 1.65
1.65
2.SpecialProcessHazards
Basefactor
1.65
1.65
1.65
1.00
1.00
1.00
1.00
1.00
E.Pressure
0.18
0.18
0.18
0.18
0.18
G2LiquidsorGasesinStorage
0.08
0.11
0.13
0.15
0.16
H.CorrosionandErosion
0.10
0.10
0.10
0.10
0.10
I.LeakageJointsandPacking
0.10
0.10
0.10
0.10
0.10
SpecialProcessHazardsFactor(F2) 1.46
1.49
1.51
1.53
1.54
ProcessUnitHazardsFactor
2.41
2.46
2.49
2.52
2.54
FireandExplosionIndex
57.90 58.96 59.80 60.43 60.98
Light
Light
Light
Light
Light
RadiusofExposure[m]
14.82
15.10
15.31
15.47
15.61
AreaofExposure[m ]
HeightofCylindrical
Volume[m]
15.10
15.31
15.47
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
biogasstoragetanksinthebiogasstation.Fromtheresults
isevidentthatdegreeofhazardfortankstosize5000m3
is only Light. And the maximal exposure area is
2
approximately766m .TheallbiogasstationintheCzech
Republic have biogas storage tank to size 5000 m3.
However some biogas stations have power up to 20 MW
(Penkun, Germany) in the Europe. Here the storage
volume of a biogas can be up to 30 000 m3. This is not
insignificant amount. The chemical industry uses the F&E
Index almost 50 years. But experience with F&E Index is
minimal in the field of agricultural and waste
management, where biogas technologies are the most
oftenused.Buthowisfromthepaperevident,F&EIndex
hasalsoaplaceinthisfield.
REFERENCES
[1] BABINEC,F.LossPrevention&SafetyPromotion.VUT
Brno, Faculty of Mechanical Engineering (2006), 39
40.
[2] COCO, J. C. Large property damage losses in the
hydrocarbonchemicalindustries:Athirtyyearreview.
NewYork:J&HMarsh&McLennan(1998).
[3] ESK BIOPLYNOV ASOCIACE: Mapa bioplynovch
stanic. Czba.cz [online]. Dostupn z WWW:
<http://www.czba.cz/index.php?art=stanice&parent=
provozovateleainvestori&nid=bioplynovestanice>
[4] Dows Fire & Explosion Index Hazard Classification
Guide, 7th edn. American Institute of Chemical
Engineers,NewYork(1994).
[5] FUERWEHRRIEDLINGEN.SchwereVerpuffungzerstrt
Biogasanlage in Daugendorf. [online]. Dostupn z
WWW:<http://www.feuerwehrriedlingen.de/einsatz
/2007/e_07_91/e_07_91.htm>
[6] GUPTA, J. P., KHEMANI, G., MANNAN, M. S.
CalculationofFireandExplosionIndex(F&EI)valuefor
the Dow Guide taking credit for the loss control
measures. Journal of Loss Prevention in the Process
Industries,16(2003),235241.
[7] SUARDIN J., MANNAN M. S., ELHALWAGI, M. The
integration of Dows fire and explosion index (F&EI)
into process design and optimization to achieve
inherently safer design. Journal of Loss Prevention in
theProcessIndustries,20(2007),7990.
15.61
This fact is presented on the Fig. 2. The dependency is

given by function y = 46.7Ln(x) + 364.4. Coefficient of
177
710
689.93 715.65 735.97 751.65 765.51

14.82
720
680
EvaluationofF&EIndexisshowedontheTab.II.Alltanks
with volume to 5000 m3 have light degree oh hazard.
HowevertheboardervalueofF&EIndexis61.Thisimplies
thatstoragetanksofbiogas,whicharebiggeras5000m3
haveModeratedegreeofhazardandhigher.Theareaof
exposureisrangedfromapproximately690to766m2.The
dependencyofradiusofexposureonthesizeofthetankis
logarithmic.
Tab.2EvaluationofF&EI
DegreeofHazard
730
690
24
C.MaterialHandlingandTransfer
740
700
Calculation of F&EI is given by the Tab. I. Only adequate

itemswereincludedinthecalculation.Items,whichwere
not adequate, were excluded (for example items such as
ToxicMaterial,RotatingEquipmentetc.).Fromthistableis
evidentthatfinalFireandExplosionIndexisrelativelylow.
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
synthesisreactor(161.7).
Tab.1CalculationofF&EI
MaterialFactor
y = 46.699Ln(x) + 364.44
R2 = 0.989
760

TheProceedings
The Investigation of Scoring Resistance on Spur Gears

MertafakTunaliolu1NihatGemalmayan2EmreOzyilmaz3
1
MechanicalEngineeringDepartment,HititUniversity,orum,Turkey,mertstunalioglu@hitit.edu.tr
MechanicalEngineeringDepartment,GaziUniversity,Ankara,Turkey,nihatgem@gazi.edu.tr
MechanicalEngineeringDepartment,HititUniversity,orum,Turkey,emreozyilmaz@hitit.edu.tr
2
3
ARTICLEINFO:
Abstract:
In parallel with the developments in technology gears for machines with an increase in speed and
Background: torque, as well as scoring the formation of teeth in the bottom of the fracture and pitting has shown
itself.
Scoring
Pitting
Spurgear
Surfaceroughness
Coatingmaterial
Scoringstrengthcalculationsduringitsformationduetotheeffectofseveralparameters
clearlyidentified.Theexperimentsofthesametypeofsteelgears,gearsarecoatedwith
Methods:
variouscoatingmaterials,intermsofscoringisdeterminedtakingintoaccountthesurface
roughnessofloadcarryingcapabilities.
Results:
Chrome,nikel,manganesecoatedgearshasmoreadvantagesthanuncoatedgears.
Whencoatingmaterialisusedatgears,Itishavingmoreadvantagesfromthepointof
Conclusions:
increasingtheirscoringstrength.
Citation: TunalioluM.S.,etal.: TheInvestigationofScoringResistanceonSpurGears,2ndInternationalConferenceManufacturingEngineering&Management2012,(2012),p.178

181,ISBN9788055312163
INTRODUCTION
gearsasresultofrapidwear.Thissystemisconvenientfor
changing the experiment parameters, to determine and
investigatethefactorswhichisaffectingtheevent.
Scoring is a case of rapid seperation of little particles

which are adhered each other by metalic contact from
gearsurfaceingearsystemsthatworksimultaneously[1].
Facing of gears by coating materails is a usual
improvement of strength method. Coating materials is
used for improving of chorosion strenght of coated
material, preventing of discountiny that exist on metals
andgainingfunctionalfeature.Byfacingofgears,scoring
strength and wear strenght are increased while the
roughness is discreased.Terauchi and others [2] has done
experimental studies on coated gears by copper,
blacklead, MoS2, zinc and phosphate to find out the
scoring strenght. In their studies, they have tried to find
out formation of scoring with rapid surface temperature
methodbyputtingatermocoupletoactivegearprofileof
gear. As a result, They have emphasazed that coating
materialshasapositiveeffectonscoringstrenghtforthe
loadcapacityandhasagoodthermaleffect.Terauchiand
others [3] have tried to find out the scoring strenght of
coated gears by copper, blacklead, MoS2, zinc and
phosphate in dry friction condition. In the result of their
studies, depends on the increase of mass tempature,
scoring is increasing rapidly, also they emphasized that
time of scoring formation goes lower range for coated
gears as in a row; uncoated, MoS2, zinc, blacklead and
copper. Tunalolu and others [4] have tried to find out
critic scoring temperature of gears by using kinds of
coating materials. They have found out on reaching
temperatureofscoringofcoatedgearsbyzinc,nickeland
mangenese.
Fig.1Thepowercirculatinggearweartestrig1.Counter2.
Reductor3.D.C.motor4.Powercontrolunit5.Coupling6.
Heatingcoolingsystemcontrolunit7.Powertransmission
gears 8. Water transmission D.C. motor 9. Power
transmissiongearbox10.Watercan11.Plainbearings12.
Torquecoupling13.Loadingbar14.Plainbearing15.Test
gears16.Testgearbox
TestGears
Gearsthatareusedinexperimentalstudiesare20MnCr5
Steel and their hardnesses are between 170220 HB. The
features of gears are shown with details in table 1.
Subscript1forpinion,subscript2forgearsareidentified
inTable1.Gearswhichusedintheexperimentsareplated
chrome,nickel,manganese.
TestProcedure
RESEARCHSIGNIFICIANCE
If there is no rapid change in weight as a result of wear

values,theexperimentiscontinuedbyincreasingtheload.
Experiments in the literature [15] 15.2 N in accordance
withthestartingscoringformationwascontinueduntilan
indication increased in increments of 20%. In the
experiments, the system's operating speed 3000 r / min,
the system operation time is 20 minutes at a time. Oil
temperature 50 C through the system in the heating
cooling device is fixed for all the experiments. 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
anddisadvantagesofusingcoatingmaterialsongears.
EXPERIMENTALMETHOD
TestEquipment
Closedcircuitpowercirculatinggearweartestmechanism
(FZG system) is used to investigate scoring strength of
178
M.S. Tunalioglu, N. Gemalmayan, E. Ozyilmaz
Inthemethodfordeterminationofcriticalscoringloadby
rapid change of surface roughness at gear profile of gear
couplethatjoinclucth,thesurfaceroughnessismeasured
after coating of gears until critical scoring load occur.
Taylor Hubson 3+ Surface Roughness Measurement
machine was used for the measuremnt of surface
roughness. Because of, the first scoring occuring is
investigated between top of gear and bottom of gear,[9
12] measurements are taken from four different point of
that area to determine thesurface roughnessand shown
asgraphics(Figure2).
resultofthetestscarriedouttodetermineloadofscoring
at a critical load and the transmitted torque values are
giveninTable2.
Tab.1Thepropertiesoftestgears
Toothformno
Numberofteeth
Module(mm)
Toothwidth(mm)
Pressureangle()
Pitchdiameter(mm)
Addendumdiameter(mm)
Dedendumdiameter(mm)
Thedistancebetweentheaxis
(mm)
Inputcouplinglength(mm)
Clutchoutputlength(mm)
Couplingratio
Toothheight(mm)
Symbol
z1
z2
m
b
o
do1
do2
Value
17
41
3
20
20
51
123
db1
57
db2
129
dt1
43,8
dt2
115,8
87
e1
e2
6,712
7,612
1,616
6
Fig.2Areasthataremeasuredthesurfaceroughnesson
toothprofile
Inordertofindcriticalscoringloadwithsurfaceroughness,
(Ra)averagesurfaceroughnessofactivegearprofileinthe
clutch and max. Topend height values at active profile
wastriedtodetermineinthemeasurements.
Tab.2Criticalloadandthetransmittedtorquevalues
Experiment
Load
TransmittedTorque(Nmm)
No
(N)
1
15,2
15200
2
18,8
18800
3
21,9
21900
4
26,3
26300
5
31,6
31600
6
37,7
37700
7
45,5
45500
8
54,6
54600
9
65,5
65500
10
78,6
78600
11
94,3
94300
12
113,1
113100
13
135,8
135800
14
162,9
162900
15
195,5
195500
16
234,6
234600
17
281,6
281600
18
337,9
337900
In order to define critical scoring load which is inside

activepairofgeartoothprofiles;
1. During the clutch gear pairs in accordance with DIN
51354rapidlossofweightasaresultofwear[6],
2. The gears that enters to clutch, the active change of
tooth surface roughness profiles [7,8], methods were
used.
In order to determine the scoring load which occurs
dependingontherapidweightlossonactivegearprofile
of gear couple which join clutch, gears were loaded with
loadings gradually from the Table 2 and the system was
worked for 20 minutes. Weights of pinion and gear are
measuredineveryloadlevel.
EXPERIMENTALRESULTS
To Determine The Critical Scoring Load With Rapid
WeightLoss
According to DIN 51354, gears were loaded gradually.
After every load stage, pinion gear removed and cleaned
from the dirt and oil, then measured with sensitive
basvular.Attheloadstageinwhichwearincreasedrapidly
andtherapidweightlosswereinvestigateddependingon
the wear, were identified as critical scoring load for the
gearthatjointhewhilethesystemisrunning,itisenough
todomeasurementsonthepiniongearinordertodefine
critical scoring load. The results of experiments for
defining critical scoring load is observed both for coated
and uncoated each pinions. The graphic of rapid increase
ofwearasaresultofcouplingisgiveninFigure3.
Fig.3 The changing of weight in the pinion to determine

thecriticalscoringload
ItcanbeseenfromFigure3,inwhichtherapidincreaseof
wearatgearpinionasaresultofclutchingevaluated,that
therapidincresementofwearisfirstlyseenonuncoated
piniongear(Kpin),secondlyonmanganesecoatedpinion
gear (Mpin), thirdly on nikel coated pinion gear (Npin)
and finally on chrome coated pinion gear (Cpin). In the
figuresindicatesthestartingpointofscoring.According
179
to figure 3, scoring is seen because of rapid wear at

uncoated pinion in 7th load stage, at manganese coated
pinion in 10th load stage, at nikel coated pinion in 15th
loadstageandatchromecoatedpinionin18thloadstage.
When we compare all test results It can be seen clearly
that the usage of chrome coated gear has more
advantagesthanothercoatedgearsanduncoatedgear.
The Effect Of Surface Roughness to The Critical Scoring
Load
In the method for Determining Critical Scoring Load with
rapiddifferenceofsurfaceroughnessatactivegearprofile
of gear that join clutch, after coating of surfaces were
done, surface roughnesses are measured until critical
scoring load was occured.In surface roughness
measurements that were done to determine critical
scoring load,average surface roughness of active gear
profile(Ra)andmax.Capendheightvalues(Ry)onactive
profile were tried to determine. Because of pinion gear
jointoclutchmorethanoppositegear,itisenoughtodo
surfaceroughnessmeasuresfordeterminingscoringload,
onconicialgear[4,5,6].
Fig.7 The average of surface roughness on crom coating

piniongear
Whenfigure4.isinvestigated,averageroughnessvalues
discreased until 3rd load stage , then it increased
gradually, and it increased rapidly where scoring occur is
investigated.Depends on the figure 4 average of
roughness of four area is between the surface roughness
values. When figure 47 investigated, average roughness
values were discreased until 5th load stage at mangan
coated pinion gear, until 8th load stage at nickel coated
piniongear,until10thloadstageatchromecoatedpinion
gear;thenitincreasedgraduallyandoccuringofscoringis
investigatedat10thloadstageatmangancoatedpinion,
at 15th load stage at nickel coated pinion, at 18th load
stageatchromecoatedpinion.
RESULTSANDRECOMMENDATIONS
Fig.4 The average of surface roughness on no coating

piniongear
Fig.5 The average of surface roughness on manganese

coatingpiniongear
In this study, scoring load that occur as a result of rapid

wearindifferentlycoatedgear,wastriedtodetermineby
considering on surface roughness. According to result of
experiments usage of coating material on gears is
advantaged for the formation of scoring. For example;
chromeplated pinion gear is worked in 11 different load
stage in 220 minutes more than uncoated pinion gear. It
showed that gear has more scoring strength than
uncoated gear. Chromeplated pinion gear reached the
scoringpointofuncoatedgearunder10timeslargerload
than uncoated gears load. As a result of a rapid wear,
experiment of critical scoring load show us; when the
coating process on gears, gears scoring resistance is
increased. Besides both gear corrosionresistant also
beautyoftheviewisgained.Duringweartestswithgears
used in coating, coating materials are mixed into oil
breaking on gears. This particules need to filter very well
fornotcauseabrasivewear.Iffigures4and7(scoringat
coatedanduncoatedmaterials)areinvestigated,whilethe
roughnessesthatresultsofproductionperiodandcoating
ofmaterialarediscreaseduntilaspesificloadvaluewhile
the period of gear couple working, occuring of scoring is
increasing gradually and while the period of scoring
occuring,surfaceroughnessisincreasingrapidly.
ACKNOWLEDGEMENTS
TheauthorswouldliketothankProf.Dr.BedriTUforhis
helpduringthework.
REFERENCES
Fig.6 The average of surface roughness on nickel coating

piniongear
180
[1] Tunalolu, M. ., (2004). Dz dili arklarda scoring

oluumunun deneysel incelenmesi. Yksek Lisans
Tezi,Gaziniversitesi,FenBilimleriEnstits.
[2] Terauchi, Y., Kohno, M., Nadano, H., and Nakamoto,
Y., (1986). Scoring resistance of spur gear with
various coathing (1st report, scoring tests under
forced lubrication). Bulletion Of JSME, Volume:29,
Number:247pp:235241.
[3] Terauchi, Y., Nadano, H., and Kohno, M.,(1986).
Scoringresistanceofspurgearwithvariouscoathing(
2ndreport,scoringtestsunderdryfriction).Bulletion
OfJSME,Volume:29,Number:249,pp:9991004.
[4] Tunalolu, M. ., Gemalmayan, N., and Tu, B.,

(2007).Kaplamal dz dililerde scoring scaklnn
deneyselyollaincelenmesi.UMES07,pp:703706.
[5] Tevruz, T., (1998). Experimental investigations on
scoring of gears and calculation by temperature
method.Wear,Volume:217,pp:8194.v
[6] Tevruz, T., (1997). Experiments of scoring and the
calculation of scoring on gears by heat method.
Wear,Volume:206,pp:204213.
[7] Goledez, S., Winter, H., and Stwe, H. P.,(1997). A
fracturemechanicsmodelforthewearofgearflanks
bypitting.Wear,Volume:208,pp:177183.
[8] Yokoyoma, M., Ishikawa, J., and Hayashi, K.,(1972).
Effect of tooth profile modification on the scoring
181
[9]
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[11]
[12]
resistance of heavy duty spur gears. Wear,

Volume:19,pp:131141.
Shipley, M., (1958). 12 ways to load test gears.
ProductEngineering,pp:7782.
Tevruz, T., (1998). Dili arklarda yenme olaynn
deneyselincelenmesi.3.UlusalmalatKongresi.
Lechner,G.,(1966).Diefressgrenzlastbeistirnradern
ausstahl,dissertation.THMnchen.
Imrek, H., and Unuvar A.,(2009). Investigation of
influence of load and velocity on scoring of
addendum modified gear tooth profiles. Mechanism
andMachineTheory,Volume:44,pp:938948.

TheProceedings
Two and Three Body Abrasion of Polymer-Particle Composites with

Fillers on Basis of Machining Splinters from Hardfacing Alloys
PetrValek1JiCieslar2MiroslavMller3
1
FacultyofEngineering,CzechUniversityofLifeSciences,Prague,CzechRepublic,Email:valasekp@tf.czu.cz
FacultyofEngineering,CzechUniversityofLifeSciences,Prague,CzechRepublic,Email:cieslar@tf.czu.cz
FacultyofEngineering,CzechUniversityofLifeSciences,Prague,CzechRepublic,Email:muller@tf.czu.cz
2
3
ARTICLEINFO:
Abstract:
Abrasionwear
Polymerparticlecomposite
Waste
Theeffectoftwobodyandthreebodyabrasiononpolymerparticlecompositescomposedof25volume
percentage of splinters from ferrous metals hardfacing alloys is discussed in this article. These
composites provide up to 26 times better wear resistance than the polymer without fillers. Wear
mechanismisexaminedinrelationtomorphologyandchemicalandphysicalpropertiesofeachdispersion
particle type. The article leads to the description of polymerparticle composites that enables material
recyclingofwasteandisusableinsomeareasofrenovationoffunctionalareasandpartsofdevices.
Citation: ValekP,CieslarJ,MllerM.:TwoandThreeBodyAbrasionofPolymerParticleCompositeswithFillersonBasisofMachiningSplintersfromHardfacingAlloys,2nd
InternationalConferenceManufacturingEngineering&Management2012,(2012),p.182186,ISBN 9788055312163
INTRODUCTION
against three body abrasion. OleaMejia [8], by presence
of 10 volume percentage of micro and nanofillers
(microsizedAl,Ag,andNi;nanosizedAlandAg)inpolymer
(branched LDPE) concluded, that the presence of Ag
particles in comparison with LDPE significantly increase
the abrasion speed, and that nanoparticles are more
efficientthanmicroparticles.Mlleret.al[9]describesthe
usefulness of microparticles in renovation processes of
functional areas of device parts by epoxy resin, in which
microparticles of Al2O3 are dispersed. Use of polymer
withanorganicalfillersareofteninareaofrenovation.Up
tillnowtheanorganicalmicroparticlesaredistributedonly
byprimarymaterials[10].
The experiment described in this article aims on

verification of a hypothesis, that a new, qualitative
materialresistanttoabrasiveenvironmentcanbecreated
byinclusionofsecondarymaterialintothepolymermatrix
thatusespropertiesofsubcomponents.Apolymermatrix
of such materials is the source of material recycling, that
shouldbepreferredamongothermethodsofdealingwith
waste. The article describes filler on basis of waste from
ferrousmetalsplintershardfacingalloysfrommachining
process. 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.
Differentphysicalandmechanicalpropertiesofcomposite
phasesdefinetheresultanttribologyproperties.Splinters
from ferrous metals are specific type of waste that is
characterized by given legislation of the given country.
Onlysuchwastethatisnotclassifiedasdangerouswaste
can be used as a filler for polymer matrix. The common
attribute of these materials is high level of hardness. In
technical practice these metals are mainly used in areas
wheretheresistanceoffunctionalareasagainstdifferent
typesofwearisrequired[1].Leeetal.[2]includeamong
the critical factors affecting abrasion resistance of hard
filler systems interface properties and geometrical and
mechanical properties of the reinforcement. Increased
hardness of polymer matrix induced by inclusion of
reinforcementaffectsthedepthofpenetrationofabrasive
particles into the polymer matrix and decreases the
amount of removed material [3, 4]. Satapathy et al. [5]
experimentally discovered on fenolic resins filled by
corundum particles with size between 40100 m that
blending of corundum increased the two body abrasion
resistance and tensile strength, and they also revealed a
correlation between hardness and wear resistance of
material. Influence of some specific anorganical particles
based on primary materials on increase of polymers
abrasion resistance is proven. Mohan [6] speaks about
perfect tribological properties of polymer matrix with
primary, anorganical materials inside, e.g. graphite and
silicon carbide that were determined on rubber wheel.
Basavarajappa[6]alsodescribesasignificantinfluenceof
SiC particles on resultant resistance of polymer matrix
METHODOLOGY
MaterialsSamplePreparation
Thepolymericmatrixofparticlecompositeswasfromthe
epoxy resin (EcoEpoxy 1200/300). These materials are
most often produced by the reaction of epichlorhydrine
withbisphenolA.Forthestructurenettingoftheseresins
connected with curing the polyamines are used. The
compound of resin and filler was created by mechanical
mixing in ultrasonic tank and hardened according to
technological requirements of the producer. Preparation
ofthecompoundwithoutvacuumwaschosenonpurpose
andinrelationtotheareaofapplicability(theapplications
withnoavailabilityofvacuuminordertoreduceexpenses
are expected). The methodical process of preparation in
theultrasonictankandhardeningoftestpiecesinaform
from twopart silicate resin partly eliminates the porosity
ofcompositesafterhardening.Testpieceswereprepared
with 25 volume percentage of filler in matrix.
Concentrationofthefilleraffectstheresultantmechanical
properties of the system. The concentration of 25% was
chosenonpurpose,becauseduetothemutualcontactof
splinters from filler the sedimentation by gravity is
minimized on this concentration. In case of lower
concentration there would be undesirable sedimentation
and in case of higher saturation by splinters the desired
cohesionofthesystemcouldbebreached.Splintersafter
machiningofvarioushardfacingalloyswereusedasfiller.
Prior machining the hardness of monolithic material had
182
Two and three body abrasion of polymer-particle composites with fillers on basis of machining splinters from hardfacing alloys
been measured acc. to Vickers (HV) by 4point pyramid

with apex angle of 136; load 294 N [11]. Price of these
hardfacingalloysiscomparativelyhigh,upto32USDkg1.
Alloy splinters were taken during machining on C11 A
/1000 lathe. Cutting plates from sintered carbide were
used, the speed of spindle 910 turnsmin1, longitudinal
displacement 0.185 mmturn1, no cutting liquid used
duringmachining(DryMachining).Describeddatareflects
the progressive technologies where higher cutting speed
and minimization of cutting liquids are preferred. The
process of machining itself together with chemical and
physical properties of the workpiece affect the creation
andmovementoftakenmaterialinformofsplinters[12].
Splintersmorphologyininteractionwithpolymermaterial
defines the resultant composite properties. For
description of the hardfacing splinters morphology had
been used optical analysis on stereoscopic microscope,
wherethepositionofsplintersin2Dplanewasobserved.
TestpieceswerealsoanalyzedbyXray.AndrexCMA357
3x3mmwasusedasasourceofradiation,parameters
focallength700mm,U=75kV,I=3mA,exposure20s.
From the point of interaction between filler and polymer
matrix perfect wetting ability of particles surface was
expected. It was necessary to define porosity (P) as an
indexofpolymercompositesquality[4](seeequation1).

P The Rea 100
The
(1)
Where:
P porosity(%),
The theoreticalcompositedensity(g.cm3),
Rea realcompositedensity(g.cm3).
Experimentaltests
The test of hardness was based on the standard SN EN
ISO20391[13].Becauseofthesizeofthefiller,aballof
hard metal with the diameter D = 10 mm was used. The
trial burdening corresponded to 2.452 kN, the burdening
time was 30 s. The two body abrasion was tested on a
rotatingcylindricaldrumdevicewiththeabrasiveclothof
the grain size P120 (dimensions of bound Al2O3 grains
125106m)accordingtothestandardSN621466[14].
Thetestingmachinewiththeabrasiveclothconsistsofthe
rotating drum on which the abrasive cloth is affixed by
meansofabilateraladhesivetape.Thetestingspecimenis
securedinthepullingheadandduringthetestitisshifted
bymeansofamowingscrewalongtheabrasiveclothfrom
the left edge of the drum to the right one. The testing
specimen is in the contact with the abrasive cloth and it
coversthedistanceof60m.Duringonedrumturnof360
itisprovokedthetestingspecimenleftabovetheabrasive
clothsurface.Consequentimpactofthetestingspecimen
simulatestheconcussion.Thepressuresforceis10N.The
mean of the testing specimens was 15.5 0.1 mm and
theirheightwas20.00.1mm.Themassdecreaseswere
measured on analytic scales weighing on 0.1 mg. The
volume decreases were calculated on the basis of the
found out volume and the density of the composite
systems. 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.
Theparticlesusedfortheexperimentweretheparticlesof
fire sand with grain size between 0.1 and 0.3 mm (the
sand for this fraction was suctioned there through mesh
screens).Thetrialspecimenwiththesize39.0 0.1mm,
24.5 0.1 mm and 8.0 0.1 mm was pressed to the
rubberdiscbyapressingforceof36.4N,thediameterof
the disc was 130 mm and the frictional distance 350 m.
183
P. Valek, J. Cieslar, M. Mller
TheapproachdescribedismodifyingtheregulationASTM
G65seeFig.1[15].
Fig.1 The machine with the rubber disc 1 funnel, 2

rubberdisc,3testspecimen,4handle,5weight
RESULTS
Prior machining the monolithic material, from which the
splinters were taken, had been tested for hardness and
chemical analysis (processed by koda a.s.), see Tab. 1.
Abrasion wear resistance of alloys is dependent on their
chemical composition and microstructure. In case of
splinters from those alloys similar properties might be
expected, despite the process of machining, thus created
heat and deformation, partially affects mechanical
properties. Variation coefficient of hardness testing was
from 3.3 to 7.9 %. High variation coefficient has been
causedbymaterialcrackingasaresultofhighbrittleness.
Removed splinters were analyzed by image analysis on
stereoscopic microscope in 2D plane (A), the standard
deviation is given by symbol (s), see Tab 2. Porosity (P),
theoretical density of the composite systems (The) based
ondensityofmonolithicmaterial(seeTab.1)andresin
(1.15gcm3) was computed. Tab. 2 also describes
distribution of hard facing alloy splinters on the area,
where the polymer composite had been exposed to two
body(Ph1)andthreebody(Ph2)abrasion.Representation
of phases was evaluated on stereoscopic microscope.
Volume reductions of the composite systems and epoxy
resin that created the matrix, created by two body
abrasion in relation to the hardness of composites or
epoxyrespectivelyareshowninFig.2.Volumereductions
of the composite systems and polymer matrix caused by
three body abrasion in relation to their hardness are
showninFig.3.Variationcoefficientofaveragevalues(in
formofvariationcoefficientonxandyaxes)isshownon
thepictures.Volumereductionofepoxyresinontwobody
abrasionwasequalto0.6030.043cm3,incaseofthree
3
body abrasion 0.0277 0.0024 cm . Temperature of the
interfaceofwornareasoftestpiecewasmeasuredduring
abrasionwearbynoncontactlaserthermometer.Average
temperature measured on two body abrasion reached
valueof35.50.9C.Incaseofthreebodyabrasionasa
result of higher velocity of abrasion particles against the
surface under wear the temperature influence increased
to 60.6 3.2 C. Measured temperatures in relation to
technological characteristics of the used resin did not
affecttheprocessofwearsignificantly. Itisobviousfrom
the results that inclusion of all hardfacing alloy splinters
intoepoxymatrixsignificantlyincreasedresistanceofthe
composite systems against two body and three body
abrasion. High variation coefficients in case of the three
significantly different between mentioned methods of

abrasion. In case of the two body abrasion grooves were
produced,seeFig.4(lightpartofthepicturearesplinters
withobviousgroovesduetoabrasivematerial,darkpartis
the matrix), when the polymer matrix and the filler were
worn by the same speed, that was directed by wear
velocity of the filler. Structure of worn surface after two
bodyabrasionisshowninFig.5and6.
body abrasion might be caused by mechanism of wear,

thereforebychippingofsplintersfromthematrix.Incase
ofthetwobodyabrasiononabrasiveclothwithgraininess
of P120 the highest resistance had composite no. 3
(volumereductionof0.02300.0008cm3),incaseofthe
three body abrasion the smallest volume reduction has
beenmeasuredoncompositeno.5(0.00700.0009cm3).
Structure of worn areas on the composite systems was
Tab.1Hardness,densityandchemicalanalysisofmonolithicmaterial
Nr.
1
2
3
4
5
6
7
8
9
10
11
12
HV
3
gcm
Fe
%
C
%
Si
%
Mn
%
P
%
Cu
%
Cr
%
Mo
%
Ni
%
609
755
546
376
803
825
745
740
589
794
826
750
7.30
7.61
7.72
7.86
7.65
7.67
7.67
7.67
7.43
7.57
7.63
7.69
Res.
Res.
Res.
Res.
Res.
Res.
Res.
Res.
Res.
Res.
Res.
Res.
3.49
3.07
2.19
1.67
3.31
3.43
3.35
3.38
3.66
3.32
3.23
3.28
1.88
1.96
1.92
1.96
1.91
1.67
1.40
1.07
2.29
2.26
2.29
2.15
0.82
0.86
0.77
0.67
0.63
0.68
0.72
0.78
0.13
0.38
0.60
1.01
0.004
0.003
0.010
0.008
0.026
0.026
0.026
0.028
0.026
0.027
0.027
0.027
0.14
0.14
0.14
0.14
0.13
0.12
0.12
0.12
0.14
0.14
0.14
0.13
2.38
2.31
2.22
2.02
2.79
2.75
2.75
2.71
2.55
2.93
3.00
3.05
0.01
0.00
0.00
0.01
0.01
0.01
0.01
0.01
0.01
0.02
0.02
0.02
4.06
4.12
4.26
4.38
3.30
3.20
3.20
3.16
3.37
3.28
3.24
3.26
Tab.2Sizeofsplinters,density,porosityofcompositesand
phasesratio
Nr.
A
2
mm
s
2
mm
The
gcm
3
P
%
Ph1
%
Ph1
%
1
2
3
4
5
6
7
8
9
10
11
12
0.6439
1.6399
1.7772
1.4897
0.5546
0.6162
0.3667
0.4292
1.1290
1.0932
0.5321
1.3318
0.3717
0.5399
0.8868
0.7392
0.2051
0.3776
0.2683
0.3037
0.4781
0.4583
0.2387
0.5918
2.7
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.7
2.8
2.8
2.8
8.8
10.8
6.5
7.0
7.7
5.4
5.7
7.9
1.8
2.5
7.5
0.8
28.8
27.0
35.8
25.8
29.5
29.8
30.5
29.6
29.9
28.9
27.2
30.0
27.4
25.8
41.1
29.5
30.1
30.7
28.9
31.0
30.4
31.8
30.6
23.6
Fig.3Surfacestructureaftertwobodyabrasiongrooves
Fig.2 Two body abrasion Volume loss of composite

systemsinrelationtohardness
Fig.4 Three body abrasion Volume loss of composite

systemsinrelationtohardness
184
Fig.5SurfaceafterwearbytwobodyabrasionNr.3
Fig.9XrayimageNr.3
In case of the three body abrasion the speed of the

polymermatrixandsplinterswerenotthesame.Polymer
matrix got worn faster than the filler, which waschipped
outofthematrixbyfreeabrasiveparticles,seeFig.7and
8.InFig.9and10thereareXrayimagesofthetestpieces
forthethreebodyabrasion.
Fig.10XrayimageNr.1
Fig.7SurfaceafterwearbythreebodyabrasionNr.3
Results have proved that the presence of splinters from

hardfacingalloysinpolymermatrixincreasedtheabilityof
material to resist described methods of abrasion wear.
Experiment has proved the results of work by Stewart et
al.[16]andKimetal.[17],whodescribedthefactepoxy
resin is easy to be filled by various kinds of anorganic
particles. Mutual interaction of particles in form of
hardfacingalloysplintersandpolymermatrixthan,similar
as nanoparticles dispersed in epoxy resin, resulted in
concordancewithclaimofKimetal.[17],toqualitatively
new materials.Similar results as those in thisexperiment
butwithuseofprimarymaterial(artificialcorundum)have
beenreachedbySatapathyetal.[5],whodiscoveredthat
inclusion of anorganic particles increased the resistance
againsttwobodyabrasion.Twobodyabrasionofpolymer
compositeswithAl2O3particleshavebeenalsodescribed
by Xian Jia et al. [18], who determined the interval in
primary corundum, that had influence on high resistance
against two body abrasion, from 40,5 to 161 m. This
interval corresponds to dimensions of some hardfacing
alloysplinters,howeveritisnecessarytotakeintoaccount
thesideofabrasiveparticles.Nevertheless,theperformed
experiment refutes results of Kumara et al. [19] and
DISCUSSION
Application of splinters from machining process of
hardfacing alloys into a polymer matrix is one of the
possiblealternativesformaterialuseofthissortofwaste.
Thisrecyclingusesthepropertiesofpolymers(e.g.epoxy
resin)andespeciallytheabilitytobefilledbyanorganical
fillers.Itisalsolowcostandenvironmentfriendly.
185
[5] SATAPATHY B.K., BIJWE, J. Analysis of simultaneous

influence of operating variables on abrasive wear of
phenoliccomposites.Wear.,253(2002),787794.
[6] MOHAN N., NATARAJAN S., KUMARESHBABU S. P.
Theroleofsyntheticandnaturalfillersonthreebody
abrasive wear behaviour ofglass fabricepoxy hybrid
composites.Journalofappliedpolymerscience.,124
(2012),484494.
[7] BASAVARAJAPPA S., JOSHI A. G., ARUN K., KUMAR
A.P., KUMAR M.P. ThreeBody Abrasive Wear
Behaviour of Polymer Matrix Composites Filled with
SiC Particles. PolymerPlastics Technology and
Engineering.,49(2010),812.
[8] OLEAMEJIA O., BROSTOW W., BUCHMAN E. Wear
Resistance and Wear Mechanisms in Polymer plus
Metal Composites. Journal of nanoscience and
nanotechnology.,10(2010),82548259.
[9] MLLER,M.,VALEKP.,NOVKP.,HRABP.,PAKO
J. Aplikace nvar a kompozit v oblasti technologie
pstovn a sklizn cukrov epy. Listy cukrovarnick
aepask..9(2011),304307.
[10] MLLER M., VALEK P. Abrasive wear effect on
Polyethylene, Polyamide 6 and polymeric particle
composites. Manufacturing technology., 12 (2012),
5559.
[11] SN EN ISO 6507191. Metallic materials Vickers
hardnesstestPart1:Testmethod,2006.
[12] NOVK, M. Surface duality hardened steels after
grinding.Manufacturingtechnology.2011:115559.
[13] SN EN ISO 20391. Plastics Determination of
hardnessPart1:BallindentationMetod,2000.
[14] ISO 62 1466. Rubber; Determination of abrasion
resistance using a rotating cylindrical drum device,
1985.
[15] ASTM G65. Standard Test Method for Measuring
Abrasion Using the Dry Sand/Rubber Wheel
ApparatusASTMG65,2010.
[16] STEWART,I.,CHAMBERSA.,GORDONT.Thecohesive
mechanical properties of a toughened epoxy
adhesive as a function of cure level. International
Journal of Adhesion and Adhesives., 27 (2006). 277
287.
[17] BYUNG CHUL KIM., SANG WOOK PARK, DAI GIL LEE.
Fracture toughness of the nanoparticle reinforces
epoxycomposite.CompositeStructures.,(2008).69
77.
[18] XIA JIA, XIAOMEI LING. Influence of Al2O3
reinforcementontheabrasivewearcharacteristicof
Al2O3/PA1010 composite coatings. Wear., 258
(2005),13421347.
[19] RAVI
KUMAR
B.N.,
SURESHA
B.,
VENKATARAMAREDDY M. Effect of particulate fillers
on mechanical and abrasive wear behaviour of
polyamide
66/polypropylene
nanocomposites.
MaterialandDesign.,30(2009),38523858.
[20] SURESHA B., KUMAR R. TwoBody Abrasive Wear
Behavior
of
Particulate
Filled
Polyamide66/Polypropylene
Nanocomposites.
JournalofAppliedPolymerScience.,119(2009),2292
2301.
Sureshaetal.[20],whofoundarelationbetweenabrasion
resistance against two body abrasion and three body
abrasionofpolymercompositesystems.Thisfacthasnot
beenprovedbythisexperiment.
DISCUSSION
Resultsoftheperformedexperiment,thatwasfocusedon
the two body and three body abrasion of polymer
composites with filler on basis of hardfacing alloy
splinters,canbesummarizedinthefollowingpoints:
Theadditionof 25volumepercentageofhardfacing
alloy splinters leaded to sharp increase of abrasion
wear resistance. Resistance against two body
abrasion increased up to 26.2 times of the original
value, resistance against three body abrasion
increasedupto4.0timesofthevalueofepoxyresin.
It can be claimed, that different morphology and

chemical and physical properties of splinters used
from machining process of hardfacing alloys have
insignificantinfluenceonresultantresistanceagainst
described two body and three body abrasion. Only
composite no. 1 was far from the resistance against
described methods of abrasion. However
morphology and physical and chemical properties
caused different measured values of composites
hardness.
In addition, no correlation has been found between

the hardness of composites with hardfacing alloy
filleritselfandresistanceagainsttwobodyandthree
bodyabrasion.
The performed experiment gives a basis for

possibilityofusesomesortofwastefrommachining
process (turning, milling, etc.) in form of fillers of
polymercomposites,especiallyreactoplastics(epoxy,
polyuretanresinetc.).
Composite systems with filler on basis of ferrous

metal splinters from machining process shall find
applicationwhensolvingproblemswithmaintenance
ofdevices,fastrepairsoffunctionalareasandworn
device parts. It is necessary to respect the complex
mechanicalpropertiesofsystems.
ACKNOWLEDGEMENT
ThispaperhasbeendonewhensolvingtheIGATFgrant.
(nr.31140/1312/3104)
REFERENCES
[1] BROEK, M. Techniceconomical evaluation of the
overlaysapplicationontheploughshares.Brno,Acta
univ.agric.Etsilvic.,(2007),129136.
[2] LEE,G.Y.,DHARAN,C.K.H.,RITCHIE,R.O.Aphysically
based abrasive wear model for composite materials.
Wear.,252(2002),322331.
[3] SUCHNEKJ.,KUKLK,V.,ZDRAVECK,E.,Abrazivn
opotebenmateril,Prague,2007.
[4] BERTHELOT J. M. Composite Materials Mechanical
Behavior and Structural Analysis, Berlin, Mechanical
engineeringseries,1998.
186

TheProceedings
A Target Trajectory Estimation with Double Exponential Smoothing

and Fuzzy Time Series
MustafaYaimli1HakanTozan2SergejHloch3
1
TurkishNavalAcademy,ElectricalandElectronicsEngineeringDepartment,34940,Tuzla,Istanbul,Turkey,myagimli@dho.edu.tr
TurkishNavalAcademy,IndustrialEngineeringDepartment,34940,Tuzla,Istanbul,Turkey,htozan@dho.edu.tr
TurkishDept.ofManufacturingManagementFacultyofManufacturingTechnologiesTUofKoicewiththeseatinPreov,hloch.sergej@gmail.com
2
3
ARTICLEINFO:
Received:21July2012/Revised:26October2012/Accepted:3October2012
Abstract:
TrajectoryEstimation
DoubleExponentialSmoothing
FuzzyTimeSeries
In this study; trajectory estimation is proposed with two different estimation techniques. By use of image processing
techniques, real time images containing tracked object from the camera are transferred to a C# based software.
After determination of centre point coordinates of the object, the trajectory the moving object is estimated with
double exponential smoothing and fuzzy time series.
Citation:YaimliM,TozanH,HlochS.:Atargettrajectoryestimationwithdoubleexponentialsmoothingandfuzzytimeseries,2ndInternationalConferenceManufacturingEngineering&
INTRODUCTION
Determinationofcollisionbetweentargetsandestimation
of the movement of a target in an environment where
bulletgetstotargetandwhichhasmorethanonetarget
likeweaponsystemsareimportantperformancefactorsof
a defense system. The literature includes algorithms to
estimate trajectory [1]. YanHua and LiXiaused a fuzzy
time series method in a similar way, while providing
greater flexibility [2]. Exponential smoothing uses a
weightedaveragebetweentheestimationoftheprevious
stepandobservedvalues,andallocatesahigherweighting
to more recent observations [3, 4]. Double exponential
smoothing is used for time series that show linear trend,
and depending on exponential smoothing. Here; as can
easlybeseenfromtheFigure1,theimagezonereceived
from the camera is scaled as 4800 horizontally and 3600
vertically[5].
ESTIMATIONTECHNIQUESOFDOUBLEEXPONENTIAL
SMOOTHINGANDFUZZYTIMESERIES
Estimationcansimplybedefinedasthepredictionoffuture
events [7]. Due to uncertainty about the object and
environment whose trajectory will be estimated, it is
difficult to determine which data should be used in
trajectoryestimation.
DOUBLEEXPONENTIALSMOOTHING
This study uses Holt's double exponential smoothing
method, which was developed for linear inclination time
series.Thismethodutilizesandsmoothingcoefficientsin
twosmoothingequations[1]:
St=.Dt+(1)(St1+Gt1)
(2)
Gt=.(StSt1)+(1).Gt1
(3)
Fig.1Cameraimage
Themidpointofamovingobjectwasdeterminedfrom
acameraimageusingC#softwareaccordingtocolorvalues,
and the destination from reference point was found using
thefollowingequation[6]:
E (x1 x2 )2 (y1 y2 )2
(1)
The software determined the location values of the

object on horizontal and vertical axes. In case of possible
circular and curvilinear movement of the object, its next
location value was found through two different estimation
algorithms.
187
Where;Stisthevalueoftheintersectionatttime,andGtis
inclination at t time. The most current actual value, Dt, is
obtained; Dt is averaged with the previous estimation of
currentvalue.Inthesecondstage,theinclinationandSt,(St
St1)valuefoundinthefirstequationisrevised.Theaverage
ofpreviousinclinationvalueand(Gt1)iscalculatedandthen
theinclination(Gt)inttimeisfound.Smoothingcoefficients
may be the same; however, in order to provide stronger
determination, a value of < is preferred in most
applications. This study takes =0.9, =0.1. Lastly, the
estimation value after steps is calculated through the
followingequation:
Ft,t+=St+.Gt
(4)
Inthisstudy,estimationsaremadebycalculatingnextsteps.
FUZZYTIMESERIES
Fuzzytimeseriesanalysesarefrequentlyusedinliterature,
due to easy applicability to data with linear or curvilinear
characteristics, and the ability to include few or many
observations without assuming observation number as
restriction. The steps of Hwang et al.s Fuzzy Time Series
(FTS)modelcanbesummarizedasfollow[817]:
M. Yaimli, et al.
A Target Trajectory Estimation with Double Exponential Smoothing and Fuzzy Time Series
Thentheestimatedvariationwillbedeterminedwiththe
followingequality;
(12)
Fv(t ) r1 ,r2 ,.......rm
First,thevariationbetweentwohistoricaldataisto
be calculated and minimum/maximum variation
values(i.e.,Dmin/Dmax)aretobedetermined,
Next step is to define the universe discourse (Ud)
withfollowingequationusingDminveDmax.
rj=Max(Rik)
(13)
And finally, the forecast value for the period t ; Ft is

computedas;
(14)
Ft=Fv(t)+At1
Ud=[DminD1,Dmax+D2]
(5)
whereD1andD2arepositiveappropriatevaluesthatfits
forseparatingUdintoequallylengthintervals.
Then, fuzzy sets on Ud are to be defined and
variation data is to be fuzzified. Defining fuzzy time
seriesFTs(t)as
where At 1 is the onestep back actual observation value

ofthetimeseries.
APPLICATION
(6)
In case of a curvilinear, circular movement of a moving

p z 1 pz 2
pzm
object,
FTs(t )
....
the next location of the target was estimated
u2
um
u1
through the developed target tracking system. The real
locationvaluesusedwereobtainedthroughtargettracking
wherethemembershipspziare0pzi1.Thefuzzysets S~i
softwaredevelopedintheC#programminglanguage.
ofUdthencanberepresentedas
APPLICATION
OF
DOUBLE
EXPONENTIAL
p
p
p
S~i
Z 1 u Z 2 u .... Zm u
1
2
m
(7)
Nextstepincludescomposingtherelationmatrix; R(t ) ,
which is governed by operation ( Ow (t) ) and criterion
matrixes ( Z (t ) ), 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 . In this step the
windows basis; w ( w 2, 3, ..., n ), have to be
determined which shows the number of periods of
variationsthatwillbeusedforforecasting.Forperiodt,
Ow (t),Z (t) and R(t ) isdefinedrespectivelyasfollow:
Z (t ) FTs(t 1) Z1 ,Z2 ,Z3 ,......Z n
SMOOTHING
Inthedoubleexponentialsmoothingapplication,thefirst10
locationvaluesfortwotypesofmovementmadebyatarget
were coded as standard, and the following values were
estimatedasthenextstepvalues.Whentheobjectmakea
curvilinearlikemotionasillustratedinFigure2.Therealand
estimatedvaluesforthecurvilinearmotionaregivenTable
1.
(8)
FTs(t 2)
O11 O12 ...O1m
FTs
t
(
3
)
O21 O22 ...O2m

w
....

O (t ) .
.
....
FTs(t w 1) O O ...O
wm
w1 w 2
O11xZ1O12 xZ1...O1m xZ m
O21xZ2 O22 xZ2 ...O2mxZ m

R(t ) ....
....
O xZ O xZ ...O xZ
wm
m
w1 1 w2 2
Fig.2aCurvilinearmotion.
(9)
Fig. 2a illustrates both the real and the estimated values

forthecurvilinearmotion.Inthesecondstage,theobject
wasmovedcircularly,asinFigure3.Atotalof32location
valueswereobtainedatequaltimeintervals,ofwhichthe
last 22 values were estimated. Table 2 shows the results
obtainedusingrealvaluesincombinationwiththedouble
exponentialsmoothingtechnique.
(10)
Let Oik xZ k Rik (for 1 i w and 1 k m )then,equation9

canberewrittenas;
R11 R12 ...R1m
R21 R22 ...R2m

(11)
R(t ) ....
R R ...R
wm
w1 w2
Fig.2bRealandestimatedvaluesforthecurvilinear
motion.
188
Tab.1 Coordinates and estimated values of curvilinear

motion.
I x
2005
300
400
500
600
750
850
1000
1100
1200
1300
1400
1600
1800
2000
2200
2400
2600
2800
3000
3200
3400
3500
3600
Iy
21005
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)
2005
300
400
500
600
750
850
1000
1100
1200
1313
1412
1511
1695
1903
2110
2316
2521
2726
2930
3134
3337
3540
3662
M. Yaimli, et al.
Tab.2Realandestimatedvaluesofcircularmotion.
Ix
1150..
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)
21005
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.
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.
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.3Realandestimatedvaluesofcurvilinearmotion.
Fig.3Circularmotion.
Figure 4 illustrates both the real position and the
estimatedvaluesforthecircularmotion.
Fig.4Realandestimatedvaluesforthecircularmotion.
APPLICATIONOFFUZZYTIMESERIES
In the fuzzy time series application, the first 10 location
valuesforatargetintwotypesofmovementwerecodedas
standard, and the next location values were estimated. In
thefirststage,inclinedshotmovementwasapplied.Inthis
stage, 24 location values were obtained at equal time
intervals,ofwhichthelast14valueswereestimated.Table
3 shows the results obtained through real and fuzzy time
seriestechniques.
189
Figure 5 illustrates both the real position and the

estimatedvaluesforthecurvilinearmotion.
M. Yaimli, et al.
inclination, despite making more errors than the fuzzy

timeseries,andgenerallyshowsbetterperformance.
Tab.4Realandestimatedvaluesofcircularmotion.
Fig.5 Real and estimated values for the curvilinear

motion.
When the object made a circular movement, 32 location
values were obtained, of which the last 22 values were
estimated.Table5showstheresultsobtainedthroughreal
and fuzzy time series techniques. Figure 6 illustrates both
the real position and the estimated values for the circular
motion.
Fig.6Realandestimatedvaluesforthecircularmotion.
Figures 7 and 8 compare inclined movement and circular
movementforevaluations.
Fig.8Circularmotion.
Figure8showsthatdoubleexponentialsmoothingproduces
smaller deviation than fuzzy time series and shows better
performance.
Fig.7Curvilinearmotion.
REFERENCES
[1] Nahmias, S., Production and Operations Analysis,

McGrawHillInternationalEditions,A.B.D.,1997.
Figure 7 shows that the double exponential

smoothingtechniqueproducessmallererrorsinupwards
190
[2] YanHua, Y., LiXia, S., On Fuzzy Time Series

Method,3.InternationalSymposiumonKnowledge
AcquisitionandModelling,298300,2010.
[3] Risteski, D., Kulakov, A., Dancev, D., Single
Exponential Smoothing Method and Neural
NetworkinOneMethodforTimeSeriesPrediction,
Conference of Cybernetics and ntelligent Systems,
741745,2004.
[4] Baojun, T., Wanhua, Q., Xing, S., "Business Failure
PredictionusingExponentialSmoothingForecasting
and Pattern Recognition", International Conference
on Risk Management and Engineering
Management,577581,2008.
[5] Yagimli, M., Tozan, H., "Fuzzy Time SeriesBased
Trajectory Estimation of a Moving Object", Recent
Advances in Neural Networks, Fuzzy Systems &
EvolutionaryComputing,161166,2010.
[6] Grnwall,C.,Gustafsson,F.,Millnert, M.,Ground
Target recognition Using Rectangle Estimation,
IEEETransactiononImageProcessing,Vol:15,No:1,
2006.
[7] Tasai, C.C., Wu, S.J., "A Study For Second Order
ModellingofFuzzyTimeSeries",IEEEInternational
FuzzySystemsConferenceII,719725,1999.
[8] Tozan, H., Vayvay O., Fuzzy Forecasting
ApplicationsonSupplyChains,WSEASTransactions
onSystems,7,600609,2008.
[9] Tozan, H., Vayvay O., A Hybrid Grey and ANFIS
Approach to Bullwhip Effect in Supply Chain
[10]
[11]
[12]
[13]
[14]
[15]
[16]
[17]
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M. Yaimli, et al.
Networks,WSEASTransactionsonSystems,8,461
470,2009.
Palit, A.K., Popovic, D., Computational Intelligence
in Time Series Forecasting: Theory and Engineering
Applications, Advances in Industrial Control,
SpringerVerlag,NJUSA,2005.
[11]Wang,C.H.,PredictingTourismDemandUsing
FuzzyTimeSeriesandHybridGreyTheory,Tourism
Management,25,367374,2004.
Li, S., Cheng Y., A Hidden Markov ModelBased
Forecasting Model for Fuzzy Time Series, WSEAS
TransactionsonSystem,5,19191925,2006.
Song, Q., Chissom B. S., Forecasting Enrollments
withFuzzyTimeSeries,FuzzySetsandSystems,54,
19,1993.
Song, Q., Chissom, B. S., Fuzzy Time Series and Its
Models, Fuzzy Sets and Systems, 54, 1993, pp. 269
277.
Song, Q., Chissom B. S., Forecasting Enrollments
with Fuzzy Time SeriesPart II., Fuzzy Sets and
Systems,62,18,1994.
Hwang, J., Chen, S. M., Lee, C. H., Handling
Forecasting Problems Using Fuzzy Time Series,
FuzzySetsandSystems,100,217228,1998.
Yagimli, M., Tozan, H., "A Fuzzy Prediction Based
Trajectory Estimation", WSEAS Transactions on
Systems,885894,2010.

TheProceedings
Selection of Equipment for Soft Tissue Cuttings Using Fuzzy AHP

and Fuzzy ANP with a Proposed Decision Support Software
LatifYANAR1HakanTozan1SergejHloch2
1
TurkishNavalAcademy,NavalScienceandEngineeringInstitute,34942,TuzlaIstanbul,Turkey,+902163952630,+902163952658
FacultyofManufacturingTechnologies,TechnicalUniversityofKoicewithaseatinPreov,08001Preov,Email:sergej.hloch@tuke.sk
ARTICLEINFO:
Received:15August2012/Revised:24September2012/Accepted:31October2012
Abstract:
In this study, 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 1.0) developed using C Sharp programming language. 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. As an application, a decision support model for determining the appropriate operation method in soft
tissue cutting process of surgical operation is proposed and performed. The alternatives, 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:YanarL.,etal.SelectionofEquipmentforSoftTissueCuttingsUsingFuzzyAHPandFuzzyANPwithaProposedDecisionSupportSoftware,2ndInternationalConference
Decisionmaking
FuzzyAHP
FuzzyANP
Waterjet
Decisionsupportsystems
INTRODUCTION
Decisionmaking(DM)isarealityofeverypartofhuman
life for thousands of years and can simply be defined as
choosing one of the alternative ways of actions
consideringtheneedsofdecisionmaker[1].Thestepsof
DMareillustratedinFigure1[2].
Step 1: Define problem
Step 2: Determine the

requirements of the
solution to the problem .
Step 3: Establish goals

that solve the problem .
Step 4: Indentify
alternatives to be
evaluated .
Step 5: Develop evaluation

criteria.
Step 6: Select a decision

making tool.
Step 7: Apply the tool to

select a preferred
alternative .

Fig.2Classificationofdecisionanalysismethods(23).
Step 8: Check the

robustness of the
evaluation .
Table 1 illustrates some of those softwares used for

MCDM problems and their solutions. In this paper, an
Analytic Hierarch Process (AHP), Analytic Network
Process (ANP), fuzzy AHP and fuzzy ANP based Decision
Support System Software (DSSS); which is named as
Decision Support Tool for Enhanced Choose (DESTEC
1.0), is developed for improving the quality of decisions
[5]ofanyMCSMandanapplicationisperformedforthe
selection of appropriate method in soft tissue cutting
processinsurgeries.Thealternatives;AbrasiveWaterJet
(AWJ) classical scalpel, and the criteria are determined
via profound discussions with experts and questionnaire
technique applied to specialists working in that field. In
thefollowingsectionsfirstthemetrologyusedinstudyis
briefly explained, and then the proposed DSSS (DESTEC
1.0) is introduced. Finally, an application to the problem
of selection of the appropriate method in soft tissue
cuttingprocessinsurgeriesisperformedandresultsand
conclusionsareillustrated.
Fig.1Stepsofdecisionmaking(2).
ThereexistvarioustypesofDMproblemsandalsomany
methods for solution of those problems in literature
(Figure 2). This study focuses on Multicriteria Decision
MakingMethodsinwhichmorethanoneobjectiveisto
bemaximized.Thistopiccanbedividedintotwogroups
as Multiattribute Decision Making (MADM) and Multi
Objective Decision Making (MODM). MODM is used to
define the problems which have a continuous decision
space and infinite criteria. MODM designs the best
alternative for the decision maker such as goal
programming. On the other hand MADM is used to
representthedecisionmakingproblemsinwhichtheaim
is to select one of the determined alternatives
considering the criteria. Here, the decision space is
discrete[3]andusuallythecriteriaareconflict[4].Inthe
literature MCDM is also used sometimes instead of
MADM just like in following sections of this paper.
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, 5, 7]. In the literature of decision making
thereexistvarioustypesofsoftwarewhichgenerallyuses
nonfuzzy methods for the solutions (see [8]) but also,
there exist a limited amount which uses fuzzy systems
andfuzzymathematics[9,10,11]forsolutions.
METHODOLOGY
AnalyticHierarchyProcess(AHP)
AnalyticHierarchyProcess(AHP)isoneofthemostused
MCDM methods, which is developed by Saaty in 1970s.
This method uses eigenvalue technique to derive a
priority vector from pairwise matrices which consists
comparisons of elements in a hierarchy of criteria and
alternatives.Uptonowthismethodisusedinmanyfields
like social, manufacturing, politics, engineering,
education, industry and government for the aims of
192
Selection of Equipment for Soft Tissue Cuttings Using Fuzzy AHP and Fuzzy ANP with a Proposed Decision Support Software
ii. Fill the comparison matrix for criteria (pairwise

matrix). Compare main criteria among themselves,
and then compare subcriteria for each main
criterion and get priority vectors. Priority vector is
obtained by
(the eigenvalue
formulation). In this formulation A is the pairwise
matrix,
is the maximum eigenvalue for pair
wise matrix and w is the priority vector [13]. There
exist several methods to derive the priority vector.
Saatyusesnormalizecolumnsandthenaveragethe
rows.Followingthiscalculation,thepriorityofeach
subcriterion is multiplied with the priority of its
parent criterion so the global priorities of each
criterionwhichwillbeusedtocomparealternatives
areobtained.
iii. Check the consistency index of the pairwise
matrices. If consistency is greater than 0.1, rebuild
the pairwise matrices because the comparisons
made in the matrix are not enough consistent to
makeareasonabledecision[13].
iv. Derivepriorityvectorsforalternativesbycomparing
themforeachsubcriterionasinstep3.
v. Synthesizethepriorityvectorsandderivetheglobal
priorityofeachalternative.
selection, evaluation, benefitcost evaluation, priority,

development,resourceallocation,forecasting[12].
Tab.1SomeoftheSoftwareusedforMCDM(Utilized
fromWikipediaand(8))
No.
Software
1000Minds
AliahThink
Choice
Reaults
Criterium
DecisionPlus
DecisionLab
2000
DecisionLens
Decision
Manager
Decision
Oven
Supporte
dMCDM
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
DESTEC1.0*
10
DecisionPad
11
DSight
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
ExpertChoice
1 8
HiPriority
19
Hiview3
1 5
AHP
AHP,
SMART
PROME
THEE
AHP
Utilily
Theory
AHP
AHP,
ANP,
FAHP,
FANP
AHP
MAUT
PROME
THEE,
MAUT
ELECT
R E I I
ELECT
REIII
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.3AHierarchicalModelforAHP.
AnalyticNetworkProcess(ANP)
Analytic Network Process (ANP) is another MCDM
method developed by Saaty in 1996, which is a
generalization of priorly explained method, AHP. In
addition to hierarchical problems, ANP also supports
problems which are modeled as a network instead of a
hierarchy.InanANPnetwork,thecriteriaarecollectedin
clusters and the influences between clusters are
displayedbyarrows.Withthesearrows,themethoduses
feedback and inner dependencies in problem, so the
result becomes more reasonable and accurate. The
clusterattheendofthearrowinfluencestheoneatthe
start(Fig.).Themethodcanbeexplainedbrieflywiththe
followingsteps:
i. Determine the criteria, alternatives and make
clustersandindicateinfluences.
ii. Establishthenetworkstructureoftheproblem.
iii. Make pairwise matrices for each criterion (node)
containing the effecting criteria for each cluster. In
pairwise matrices the same comparison table in
AHP is used, and the priority vectors are calculated
in the same way. Here, alternatives are treated as
othercriteriaintheproblem.Thentheclustermatrix
isestablishedwhichincludesinformationabouthow
eachclusterinfluencestheothers.
iv. Establish unweighted supermatrix using priority
vectors of the pairwise matrices established for
each criterion. Then in this supermatrix, multiply
every cluster block with the element corresponding
that block in the cluster matrix and obtain the
weightedsupermatrix.
*Decision Support Tool for Enhanced Choose. (This is the

so ware is developed by writers of this paper) Interac ve
Robustness analysis and parameters Inference for multiple
criteriaSortingproblems.
Mul pleFunc onEvalua onProcess
Toelucidatethemethodthestepsareexplainedbelow:
i. Define the problem and goal, and determine your
criteria(andsubcriteria,ifthereare).
193
L. Yanar et al.
L. Yanar, et al.
v. Following this find the limiting matrix by getting

powers of weighted supermatrix (If limiting matrix
cannot be achieved by getting the powers of the
matrix,useCesaroSummethod[14,15]).
vi. In limit matrix all columns are the same and the
values in the lines shows the global priority of each
criterionforthenetwork.Herewecanhavethelocal
priorities of alternatives (as any other criterion) by
normalizing the priorities of alternatives in
alternativescluster.
, perform a fuzzy addition operation

To obtain
ofmextentanalysisvaluesforaparticularmatrixas;
,
and to obtain
addition operation of
follow;
perform the fuzzy

1, 2, , values as
Finally, compute the inverse of the vector in the

proceedingequation;
1
FuzzyAHPandFuzzyANP
Fuzzy set theory is introduced to the literature by L.A.
Zadehin1965(16).Zadehdefinedthefuzzysetasaclass
ofobjectswithacontinuumofgradesofmembership.In
fuzzysets,themembershipdegreeofanelementdiffers
intheintervalfrom0to1whileinacrispsetitisbasically
0 or 1. This membership degree is derived from a
membershipfunctiondefinedforeveryfuzzyset.Infuzzy
calculation fuzzy numbers are used which are basically
fuzzy sets that typically in types like triangular,
trapezoidalandetc.thataregenerallynamedduetotheir
shapes.Thetriangularmembershipfunctionisillustrated
in
Andcanbeexpressedas:

and
is
1 ,
0 ,
,
wheredistheordinateofthehighestintersectionpointD

(Fig.6)
between
1)
Fig.6IntersectionofFuzzyNumbersM1andM2.Source:
(19)
Step3: The degree possibility for a convex fuzzy

number than k convex fuzzy numbers
,
1,2,3, , canbedefinedby
ThereareseveralapproachestofuzzyAHPandFuzzyANP
methods but in this study Changs Extent Analysis
selectedandusedduetoitscommonusageandsimplicity
[17, 18, 19]. Changs extent analysis can be briefly
summarized as follow [17, 18, 19, 20]: Let
, , ,..,
is
the
object
set
and
, , ,,
isthegoalset.Inthismethodfor
eachgoaliextentanalysisisperformedforeachobjectj,
and m extent analysis values are obtained:
,
,

,
1, 2, 3, , where
s are
triangularfuzzynumbers.
Step1: Fuzzy synthetic extent value Si is obtained for
eachobjectibytheequationbelow:
Assuming
1,2, ;
where
194
Fig.5TriangularFuzzyNumber
Step2: For two fuzzy numbers

,

, ,
, the degree of possibility

definedas
Fig.4ANPNetwork
,,
min

,
1,2, ,
min
for

,theweightvectorthancanbegivenas
T
,
,,
,
1,2, , are elements.
Step4:
Via normalization, the normalized weight vectors can be
givenas
T
,
,,
where isanonfuzzynumber.
Developed Decision Support System Software, DESTEC
1.0
DESTEC .1.0 is a C Sharpbase DSSS developed to handle
the sophisticated MCDM problems. The most important
features of DESTEC is to allow to the decision maker to
use different methods at the same time including two
fuzzyMCDMmethods.Thesoftwareenablesthedecision
makertouseAHP,FuzzyAHP,ANPandFuzzyANPbothin
L. Yanar et al.
the same timeor separately. The data entry by the user

onlyinvolvesthenecessarydataneededforAHPorANP
to the sheet provided by DESTEC. Following the
calculation,theresultsaredisplayedontheuserinterface
oftheDESTECindetailsorinshortformaccordingtothe
choice of the user so that the Weighted crisp and fuzzy
supermatrices along with the limit matrices can be
displayed. This allows the user to see the influences of
each element in problem for ANP models. DESTEC uses
the algorithm of Williams Adams, the developer of the
Super Decisions software, for limit matrix calculations
[21]. The flow diagram for limit matrix calculations is
illustratedinFig.7.
Fig.7Flowdiagramforlimitmatrixcalculation
ThestepsforusingthesoftwareareshowninFig.8,andthe
user interface and Excel sheetsare displayed in Fig. 9, Fig.
13.
Fig.9TheuserinterfaceofDESTEC1.0
Fig.8StepsforusingDESTEC1.0.
195
L. Yanar, et al.
Fig.13TheuserinterfaceofDESTEC1.0aftercalculation
showingresultsandsupermatricesandlimitmatrices
ProposedModelandApplication
In this study AHP, ANP, Fuzzy AHP and Fuzzy ANP models
for surgery equipment selection for soft tissue cutting
process are proposed and solved using DESTEC 1.0. The
alternativesforthesolutionoftheproblemaredetermined
asclassicalscalpelmethodandAbrasiveWaterJet(AWJ)
technology. AWJ is a technology that cuts material with
pressured, abrasive particles including water [2224]. This
technology is widely used in many areas in industry for
cutting materials like wood, metal, plastic, rock [2224].
Recentlyitisstatedtobeusedinmedical.Anexamplefor
AWJusedinmedicaloperationsisshowninFig..
Fig.10ExcelsheetofDESTEC1.0forproblemdefinition
Fig.11ExcelsheetofDESTEC1.0forinfluenceentrancefor
ANPandFANP.
Fig.12ExcelsheetofDESTEC1.0forpairwisematrices
Fig.14AWJEquipmentusedinsurgeriesanditsapplicator
nipples(25)
In the study, alternatives and criteria are determined via
profound discussions [25] with experts and questionnaire
technique applied to specialists working in that field in
Presov/Slovakia. The AHP model and ANP models for the
problemareillustratedinFig.14andFig.15respectively.
Inthismodelthemaincriteriaholdsthemethodsusedfor
detecting the disease. 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
tissuechangingthecuttingpressureoftheAWJ.Theother
maincriteriacontrolholdsmanualandautomaticwhich
represents the usage of the equipment. The main criteria
economicimpactholdsthesubcriteriaaboutthecostsof
the equipment. And finally, 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
representstheabilityoftheequipmentaboutselectingthe
material(tissue)tobecutoruncut.ForAWJ,itisadjusted
196
bychangingthepressureofthewaterwhilewithscalpelit
istotallytheexperienceofthesurgeon.
[5]
[6]
[7]
[8]
[9]
[10]
Fig.15TheAHPmodeloftheproblem
[11]
[12]
[13]
[14]
[15]
Fig.16ANPModeloftheProblem
Theinfluenceswhicharedeterminedbytheexpertforthe
ANPmodelarealsoshownindetailswithfig.16.
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(seeFig.15).Asitcaneasilybeseenfromthe
Table 2, difference between the results of fuzzy methods
arebiggerthatcrispones.
[16]
[17]
[18]
[19]
CONCLUSION
In this study a generic DSSS; named as DESTEC 1.0, is
presentedthatenablesthedecisionmakertouseAHP,ANP
and their fuzzy models together which makes the DSSS
special.AstoourknowledgenootherDSSSisbothableto
solveallfourmodelsandnotbeingproblemspecific.With
theuseoftheproposedDSSS,thedecisionmakercangain
theabilityofevaluatingthealternativesfromawiderview
thatmayprovideabetterdecision.
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TUKE.

TheProceedings
Quick Systems in Planning and Project Management: A Structured

Approach for developing a new project
ShakibZohrevandi1
1
TSTACompany,PayamNoorUniversity,Iran,Email:shakibzohrevandi@gmail.com
ARTICLEINFO:
Abstract:
ManagementSystem
ProjectControl
ProjectManagement
ProjectPlanning
QuickProject
Variety of ways to planning and project management so far has been studied and has been used by
managers and related professionals.This paper is basedon a case study and literature review, aSystem,
entitled hereafter repetitive and ocular project management system, applying quick project management
principleswasdeveloped.Afterthesystemimplementation,aqualitativeevaluationwascarriedoutbya
document analysis and questionnaire application. Time is an important factor in the implementation of
these methods and for doing rapid and timely for project managers, plays a vital role. Therefore, the
researchisforimplementationofrepetitiveandocularprojectmanagementsystem.Thewayistodealwith
thegrowingdemandforprojectsthataimistodevelopnewproductsissuitable.Thispapershowsthatthe
application of this system at the companies under investigation evidenced the benefits of using simple,
repetitive,ocular,andquicktechniquestoplanningandcontrolinnovativeproductprojectscombinedwith
traditional project management best practices, such as standardization. In this paper, we try to project
managementbestpracticesisnotonlyinliterature,yeaitcanbeappliedinpracticethatcanbeuseitin
types of projects for implement a system of planning and project control based on quick project
managementprinciples.
Citation: ZohrevandiS. QuickSystemsinPlanningandProjectManagement:AStructuredApproachfordevelopinganewproject,2ndInternationalConferenceManufacturing

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, for
example quick software development. The best practices
in project management from 1960 onwards have been
published widely, including (Crawford 2006[1],
Kloppenborg & Opfer 2002[2], Kolltveit, Karlsen, &
Gronhaug 2007[3], Shenhar & Dvir 2007[4], Sderlund
2004[5]),therearesomebarrierswhenthesepracticesare
applied to innovative and complex projects, especially
concerning product development[6]. 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. These activities include requirements, design,
coding, and testing processes based on a minimal set of
activitiesneededtoreachtheendgoalaworkingsoftware
system Although some of these quick development
systems address the management aspects of software
projects, people, processes, and technology they are
primarilyfocusedoncoding,testing,andsoftwareartifact
delivery. Project managers are used to dealing with an
evergrowingdemandforprojectsthataimatdeveloping
innovative and complex products. Quick techniques are
bestusedinsmallscaleprojectsoronelementsofawider
programofwork,oronprojectsthataretoocomplexfor
the customer to understand and specify before testing
prototypes.Aprojectcomplexitydefinitionisnecessaryin
order to cope with project management challenges. [7]
Quick project management approaches have emerged to
assisttheadaptationofconsolidatedprojectmanagement
practicestoimprovetheseprojects.However,fewauthors
have proposed welldefined and pragmatic methods to
apply these approaches or provided systematic
evaluations of their results. One of the challenges that
companiesmustfaceisthedevelopmentofnewtoolsand
systems to suit specific project management

environments.Thisarticleproposesamethodforplanning
and controlling innovative product projects using quick
project management principles, followed by a procedure
touseit,andtheresultsoftwoimplementationcases.
LITERATUREREWIEW
How do companies plan and control projects of new
products in a project environment laden with
uncertainties?Inanattempttoanswerthisquestion,aset
of principles and concepts for innovative product
development projects has recently emerged from the
softwaredevelopmentarea[8],knownintheliteratureas
quick project management. Quick project management is
a set of values, principles, and practices that assist
project teams in coming to grips with this challenging
environment, 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]. Quick project management
principles, similar to Lean Thinking principles [10], are
based on flexibility and simplicity. Theyare developed by
iterations and add value to customers by means of short
time deliverables [11]. Core quick project management
valuesare[12]:Employrepetitivefeaturedelivery,deliver
customer value, champion technical excellence, build
adaptive teams, encourage exploration, simplify. Quick
projectmanagementfocusesonpeopledevelopment,self
management and selfdiscipline, participatory decision
making, customer focus, and less bureaucracy. Although
the literature on quick project management proposes a
setofvaluesandprinciplestobeappliedinthecontextof
innovativeproducts,therearenotmanyempiricalstudies
evaluating the effectiveness when applied to the
developmentofprojectmanagementtoolsandsystems.
198
Quick Systems in Planning and Project Management: A Structured Approach for Developing a New Project
processes for project management [20].However, some

authors,suchasWhiteandFortune(2002),haveidentified
that a restricted set of systems and tools are used in
practice, of which project management software and
Gantt charts are the most relevant. In addition,
theoretically, research on project management has taken
into account common assumptions, such as prescriptive,
normativetheory,groundedonidealprojectplanningand
control models [21]. Project planning is a discipline for
stating how to complete a project within a certain
timeframe, usually with defined stages, and with
designatedresources.Oneviewofprojectplanningdivides
theactivityinto[22]:
Settingobjectives(theseshouldbemeasurable)
Identifyingdeliverables
Planningtheschedule
Makingsupportingplans
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. Another study[23]
withtransnationalcompaniesalsoevidencedthewideuse
of Gantt charts by project managers to plan and control
projects, but with limited results. Chin suggests most
innovative products are developed under uncertainties in
turbulent environments, characterized by project
complexity, unpredictable activities, and changes where
the traditional approaches have presented limitations.
Despite the extensive literature available on project
management[24], there are few studies that present
advances on how to plan and control innovative product
projects.
The quick project management approach is indicated for
innovative product development projects, Highsmith
suggestssomedirectionsforprojectplanningandcontrol.
Forexample,aprojectplanshouldstartwiththeproduct
vision (vision box and elevator test statement), followed
bythedefinitionoftheprojectscope(projectdatasheet),
and end with the project plan (repetitive feature plan).
However, there are two aspects to be considered. First,
the majority of the quick project management proposals
cannot be properly considered as techniques. In the
perspective of traditional project management best
practices, such as a Gantt chart, program evaluation and
reviewtechnique,andcriticalpathmethod,atechniqueis
based on a wellestablished theory with wellspecified
proceduresforitsuseandimplementation.Iterationsand
other quick project management recommendations do
notaddressthiswidespectrumandhavebeentreatedas
guidelines and principles that are not supported by the
literature.Thesecondaspectreferstotheguidelines.They
must be appropriately evaluated because not many
studies have evaluated these applications. In turbulent
environments, product development projects rarely end
according to the original plan [25]. Steffens et al. also
emphasize that in the traditional project management
approach, changes are negative aspects, whereas in
turbulent environments they are prerequisites to
successfulprojects.
PROJECTMANAGEMENT
Projectmanagementisacarefullyplannedandorganized
effort to accomplish a successful project. Project
management includes developing a project plan, which
includes defining and confirming the project goals and
objectives, identifying tasks and how goals will be
achieved, quantifying the resources needed, and
determiningbudgetsandtimelinesforcompletion.Italso
includesmanagingtheimplementationoftheprojectplan,
along with operating regular 'controls' to ensure that
there is accurate and objective information on
'performance'relativetotheplan,andthemechanismsto
implement recovery actions where necessary[13]. Project
Management is an important topic because all
organizations, large and small, are involved in
implementing new undertakings as diverse as the
development of a new product or service, or a public
relations campaign. To keep ahead of their competitors,
every organization is faced with development of complex
services and processes. These need cross functional
expertiseinagivenorganization[14].
BeforetheprinciplesofquickProjectManagementcanbe
defined,asetofunderlyingvaluesareuseful:
Communication of information within and outside a
quickprojectisconstant.
Simplicity, defines the approach to identifying the
critical success factors of the project in terms of the
simplestpossiblesolution.
Courage, all important decisions and changes in the
direction of the project need to be made with the
courage.
Humility, the best project managers acknowledge
theydontknoweverything.
According to the Software Engineering Institute, a
methodology must possess certain attributes in order to
meettherequirementsofbeingcalledamethodology[15].
Figures1describehowtheseattributescouldberelatedin
quickprojectmanagementsystems[16].Thisstructureisa
process pattern view of project activities[17]. This
approach focuses on the communication and people
centric aspects of project management. Quick project
managementcanbebuiltonthisframework.
Fig.1InterrelationbetweenProjectManagementActivities
PROJECTCONTROL
PROJECTPLANNING
Put simply, Project Controls encompass the people,

processes and tools used to plan, manage and mitigate
cost and schedule issues and any risk events that may
impact a project [26]. Project control implies observing
project execution so that potential problems may be
identifiedinatimelymannerandcorrectiveactionmaybe
addressed, whenever necessary, to control the execution
of the project (PMI, 2004). Similarly to project planning,
the control process includes many tools and techniques.
Thekeytoasuccessfulprojectisintheplanning.Creating
a project plan is the first thing you should do when
undertaking any kind of project [18]. There are many
techniquesandmethodstomanageprojects,eachonefor
a specific project management process [19]. The
successful performance of a project depends on
appropriate planning. The PMBOK Guide defines the use
of 21 processes that relate to planning out of the 39
199
S.Zohrevandi
S. Zohrevandi
review.Figure2presentstherepetitiveandocularproject
management system; its components, followed by their
description; and a seven stage procedure to use the
system. All five components of the repetitive and ocular
project management system were integrated into
planning and control projects in a simple, ocular, and
interactiveway.
ThedevelopmentofasuitableProjectControlsystemisan
importantpartoftheprojectmanagementeffort[27].This
study focuses only on scope, time, and deliverables
control. The literature on project control presents many
dimensions and approaches to apply control techniques
andtools.Rozenes,Vitner,andSpraggett(2006)provided
an extensive review of the literature on project control.
Theyconcludedthatintheprojectmanagementliterature
authors use a onedimensional control system in spite of
notintegratingprojectobjectivesatall.Rozenesetal.Also
found evidence that the most utilized multidimensional
controlsystemistheearnedvalue.ThedisadvantageofEV
analysis is its lack of integration with other project
dimensionssuchastechnology,quality,anddesign.
The role of quick project management control and
planning surpasses merely taking corrective actions and
following plans (Highsmith, 2004). Quick project
management control plays an important role in learning
inprogressandnotfollowingarigidplan,whichdoesnot
imply that the control process or standardization and
procedures should be given up, according to Highsmith.
Highsmith emphasizes the definition of what control. He
discusses the necessity of simplicity, added value to the
customer, and focus on leadership and development of
team competences. He also argues that if plans are
speculations or hypotheses about the future, then
frequent and effective feedback is required to test them.
Considering the context and values derived from the
application of quick project management principles to
project management practices, Highsmith noted a self
disciplined and self managed team development. The
success of projects that adopt the exploration approach
dependsonrealitybasedfeedback.Adaptingtheplanand
project scope depends on apprehending a wide range of
information,whichincludestheassessmentoftheproject
progress, technical risks, evolution of requirements, and
ongoing competitive market analysis, argued Highsmith
(2004).
Fig.2 Repetitive and ocular project management system

basedonquickprojectmanagement
ProjectDeliverablesModel:
The phase and project deliverables model combined the
principles of stagegates [29] and project lifecycle
management. Some standard phases and deliverables
weredefinedtoguidetheprojectplanningandexecution.
ProjectDeliverablesModelalsoincludesasimplifiedsetof
templates used to collect, document, and organize all
project information produced. The templates have two
objectives: to organize the project information and to
guide the documentation and standardization of project
process.
Planningandcontrollingboard:
The Planning and Controlling board was designed to
integrate the project phases with the deliverables in a
simple timescale. The deliverables can be defined
according to their execution phase. The project planning
focuses on defining deliverables instead of activities. At
this stage, the project team does not define the exact
work that must be done, but only what is going to be
delivered,becausetheydonotyethaveaclearviewofthe
tasks and activities; they are only certain of the project
goals and mission. The deliverables are inserted in the
whiteboardusingcoloredstickynotes.Eachprojectusesa
differentcolor,andthedeliverablesareorganizedonthe
boardaccordingtoatopdownprioritysequence(highest
priorityatthetop).
WeeklyPlanningboard:
Thiswhiteboardisusedtodefinesomeactivitiesandwork
packages. Each activity is connected to one or more
Planning and controlling board deliverable. The Weekly
Planning board uses an iteration concept, by having fast
short time results. The whiteboard has the weekdays
printed at the top, divided into two periods on each day
(morningandafternoon).WeeklyPlanningboardalsouses
stickynotestoshowtheinputoftasks,activities,andwork
packages.
PerformanceIndicatorprocedure:
A simple set of performance indicators was adapted to
measure the lead time of deliverables by means of EVA.
Basedontheprojectbaseline,theprojectismeasuredin
RESEARCHMETHOD
Theresearchmethodwasdividedintofourphases:
a) A systematic literature review was carried out to
identify empirical studies of implementations of quick
systems in innovative product development projects,
whichindicatedissuestobeinvestigatedinthisfield.
b) A diagnosis of project management practices was
carriedoutatasmallcompany,wheresomeproblemsand
difficultiesinprojectmanagementwereidentified.
c) A method to plan and control projects was developed
by means of action research [28], and subsequently
implemented.
d) After the implementation, the system was evaluated
usingacasestudymethod(Yin,1989).Datacollectionwas
carried out through interviews, weekly observations, and
documentanalysis.
A questionnaire was applied to address two research
questions:
1.Did the system benefit the company project
management?
2.Coulditbeconsideredquickly?
Thedatacollectedwereanalyzedinaqualitativemanner.
Itisimportanttoemphasizethattherearemanyoutputs
and activities in the planning and control phases (PMI,
2004), but only the project scope, time, and deliverables
wereevaluatedinthisstudy.
PRESENTPROJECTMANAGEMENTSYSTEM
The system developed is entitled repetitive and ocular
projectmanagementsystem.Itwasbasedonquickproject
management principles as described in the literature
200
terms of time spent, current progress, value added, and

deviation plan. The Performance Indicator procedure is
notappliedtoresourcescontrol.
7.5.Projectmanagementsoftwareforportfoliocontrol:
Quick software development is a group of software
development methods based on repetitive and
incremental development, where requirements and
solutions evolve through collaboration between self
organizing,teams.ThesoftwareisDotProjectandconsists
ofanonlineInternetbasedandopensourcesoftwarefor
project management. A customized module was
developedtogenerateprojectperformancereportsbased
on the Performance Indicator procedure. The role of the
software is quite different from traditional project
management.Itpromotesadaptiveplanning,evolutionary
development and delivery, a timeboxed iterative
approach, and encourages rapid and flexible response to
change[30] . It is not used for planning and controlling
projecttasks,butforregisteringprojectdatatoenablethe
teamtomakedecisionsandmanagetheprojectportfolio.
The team uses the Planning and controlling board and
Weekly Planning board to plan and control projects.
Described next are seven stages that represent a
procedure to use the repetitive and ocular project
management system, as shown in Figure 2, but some
changes were made in Project Deliverables Model and
Planning and controlling board components, especially
concerning timescale positioning. It starts with the
demandforanewproject(step1).Bymeansofaproject
plan template, the risk analyses and most of the product
requirements are defined. Changes may occur, but it is
importanttohaveageneralviewoftheprojectgoalsand
constraints.Theprojectteamdefinesthedeliverablesand
the phases of the Project Deliverables Modelbased
project,takingintoaccountitsdeadlines,constraints,and
goals. The project manager and the team insert the
deliverablesonthePlanningandcontrollingboard(step2)
according to descriptions of the project phases. Each
phasehasstandardactivities.ThePlanningandcontrolling
board deliverables are inserted by means of different
coloredstickynotes(onecolorforeachprojectincasethe
companyhasmorethanone).Eachstickynoterepresents
adeliverableandcontainsthedeliverablenameandshort
description,estimateddeliverydate,andpersonincharge.
Each sticky note is organized on the Planning and
controlling board according to its priority, phase, and
delivery date. Once the deliverables are placed on the
Planning and controlling board, they must be uploaded
onto the software (step 3). Thesoftware was customized
to fulfill the Planning and controlling board and Project
Deliverables Model standards. It has templates of each
phase and deliverable to guide users in their work. The
software deliverables must have the estimated starting
and ending dates to enable the baseline creation. The
project managers, with all team members, were able to
define,atweeklyshortmeetings(average40minutes),the
work packages by decomposing the deliverables into
measurabletasks(step4).Teammembersinputthetasks
intotheWeeklyPlanningboardbymeansofstickynotes.
The information on these sticky notes comprises the
deliverable name, task name, person in charge, and
estimatedenddate.Thestickynoteisinsertedontheday
of the week that the work starts. The team member can
breakthetasksandevenreorganizehisorherscheduleto
better respond to project changes. Once a WP is
completed, the person in charge of it logs in on the
softwareandinsertsabriefcommentwithrespecttothe
task, and the percentile of each task represented by the
deliverabledefinedonthePlanningandcontrollingboard
(step5).Atstep6,thesoftwaregeneratesthereportswith
project performance indicators, as defined in the

PerformanceIndicatorprocedure.Thereportsareusedto
control the project progress, value added, deviation, and
time spent. At step 7, the project team analyzes the
informationfromthesoftwarereportsandusesittocheck
the value added to customers, their learning about the
projectuncertainty,andtheprojectprogresstobeableto
takeadaptiveactionsandanticipatechanges.Allstagesof
this method have been designed to be repetitive,
integrated, and repeatable during the project life cycle.
The quantity of iterations will depend on the type of the
project; its complexity and uncertainty level must be
considered. A repetitive project lifecycle management
implies defining deliverables, inputting them into the
software, defining, executing, controlling work packages,
andinformingtheprojectteam.
CASEAPPLICATION
Foundedin2003inBrazilCountry,theCompanyisasmall
company that develops highly technological products
involving hardware and software. That is specialized in
computerprogrammingandintegrativehardwaresystems
foreducationandentertainment.Thesystemwasapplied
to one of its projects in which the goal was to develop a
robot for education and research computer laboratories.
The robot includes features that can be reprogrammed
usingmodularprogramming.
Fig.3 Results of the answers from the data interview

reports.
SYSTEMEVALUATION
Aquestionnairewaspresentedto19participantsthathad
applied the method. Figure 3 shows the percentile
frequency of the answers regarding the system analyses
considering the following criteria: 1 encourages project
innovation and creativity, 2 repetitive and ocular project
managementsystemrequiredteamselfdisciplineandself
management, 3 self discipline and self management
contributed to better project team performance and
development, 4 added value to the team and customer,
5 repetitive and ocular project management system
provided to ocular communication and team view, 6 the
ocular communication contributed to better project
results,7flexibilitysuitstheprojectchangesrequirement,
8simplicity,Eachcriterionisdiscussedintheparagraphs
that follow. Has the system encouraged innovation and
creativity (1)? According to 68% of the respondents, the
method enabled process creativity and innovation. But
32% were indifferent or disagreed. This aspect is critical
andrelevanttotheirworkduetotheinnovativenatureof
productdevelopment.Thesystemprovidedaccuratedata
and organization without adding much bureaucracy to
theirprocess.Theywereabletoadaptinfaceofchanges.
The need for self discipline and its impact on the
companiesandtheirprojectswereevaluated.Ninetyfour
percent agreed that repetitive and ocular project
managementsystemrequiredselfdiscipline(2),and100%
agreed that self discipline had a positive impact on and
improvedprojectresultsandteamdevelopment(3).
201
S.Zohrevandi
S. Zohrevandi
With respect to the value added to customers and the

project team (4), the graph shows that 100% of the
respondents agreed that repetitive and ocular project
management system added value to customers. A critical
andcontroversialpointmustbeaddressedhere.Boththe
approaches, traditional and quick, can add value, but in
the cases in question, there is ample evidence that a
simplewayofplanningandcontrollingprojectsbymeans
of sticky notes and a whiteboard, with the support of
project management software, and a simple set of
templates contributes more to customers and project
teams than does using concepts based on traditional
planning and control tools. Iterations with customers, by
meansofregularphasereviewmeetings,helpedtheteam
deliver exactly what the customer expected. In the
company, the project manager expressed that their
customers enjoyed the results and the project
organization and procedures adapted. Concerning the
ocular communication aspect, 68% agreed that repetitive
andocularprojectmanagementsystemcontributedtothe
project team view (5) and 78% agreed that the ocular
communication provided by the method contributed to
betterprojectresults(6).Inthecompany,teammembers
highlighted the repetitive development of all project
phases and deliverables during the system application. In
addition, the project manager became more confident
abouttheresults:Itsocular;itseasytocheckwhetheror
nottheprojectisrunningsmoothly.
With respect to project flexibility (7), 73% of the
participants agreed the method is flexible and enabled
project changes. Before the system was implemented,
theywerenotabletomeetprojectchangesrequestedby
customerandmarketchanges.Theyhadtofollowarigid
plan. The regular customer iteration inherent to this
methodpromotestheidentificationofchangesduringthe
review of the phase gates. As regards simplicity (8), 74%
were indifferent or disagreed that repetitive and ocular
project management system is simple to use. Although
only26%agreedthatthesystementailedsomesimplicity,
most agreed that it improved their project management
skills. Regarding research question 1, the project
management role in the company became faster than it
had been (i.e., when they had to define all tasks and to
develop an entire project plan by means of traditional
project management systems). Their focus clearly moved
from project planning to project exploration (execution)
(Chin, 2004; Highsmith, 2004). A parallel evaluation was
carried out and included a qualitative analysis based on
the data collected during the implementation process, as
discussednext.
Regarding process and standardization by means of
Project Deliverables Model, the team developed a
commonviewthatprovidedabetterunderstandingofthe
project deliverables and phases for the Company. They
usually had to reinvent the project process and
documentation templates to register project information.
The templates provided a historical file of the entire
project, enabling a fast retrieval of any project
information, which refers to question 1. Project
DeliverablesModelworkedasastandardbyprovidingthe
companywithanoverviewoftheprojectmanagementlife
cycle. Analyzing project scope, deliverables, and tasks
execution,thePlanningandcontrollingboardandWeekly
Planningboard,inturn,providedtheteamwithaholistic
viewofthemajorprojectdeliverables.Thisisaocularand
repetitive way for project planning and controlling by
meansofstickynotesandwhiteboards.Theteamgotused
todiscussingprojectdeliverablesthroughprojectprogress
onaweeklybasis,andtakingadaptiveactions,whenever
theyjudgednecessary,tofulfilltheprojectgoalsandadd
202
value to customers. By controlling tasks and reports

through the software and a simple set of KPIs faster and
accurate performance can be easily checked. In addition,
the software provided a chronological account of the
project data covering its entire life cycle. Reports were
automatically generated. The software assisted in the
registrationofprojectdatabycreatingasinglefileofthe
projecthistory,thusenablingpreventiveactions.
Regarding research question 2, by analyzing the
organizational benefits, although the implementation in
theCompanywasfastduetoleadershipcommitmentand
project team motivation, project management activities
were reliable and organized in the company. The ocular
and simplicity related aspects of the system have
contributed to project flexibility, a sine qua non in their
project environment. Some disadvantages arose during
the implementation (e.g., the necessity of self managing
and self disciplined capabilities to use the method). Each
teammemberneededtocontribute,evaluate,anddiscuss
the role of project management in the quick project
management approach. Leadership and participant
decision making are mainstream and are rooted in the
lean thinking approach. The use of this system with
project management software helped to reduce planning
timeandimprovecommunication:Nowwecansee,every
day, without much effort, what we have to do, not only
theprojectmanager,butalltheprojectteammembers;It
became easier to discuss project deliverables in view of
Planning and controlling board. On the subject of some
specific characteristics of the method, such as visibility,
user friendliness, and agility, the team members agreed
thatitsavestimeinplanningandfocusesontheexecution
phase.
CONCLUSION
Due to the characteristics of the chosen investigation
design, this study presents some limitations. It does not
mean to neglect the best project management practices
available in the literature, nor does it intend to advance
generalizationstoalltypesofprojectandcompanies.For
the specific companies under consideration, which
develop innovative products, the results evidence the
feasibility of adopting a quick method with simple and
flexible techniques to plan and control projects despite
their perception. Their projects are developed locally,
which involves uncertainties and dynamic work requiring
creativity, innovation, and flexibility. In this context, the
system has contributed to improve their project results.
This study has also identified that it is possible to have
benefitsthroughthecombinationofadvancedtechniques
to manage a group of projects (such as software and
metricsbasedintime)andsimpleandoculartechniques,
which may be useful in the management of the project
teamschedule.Thisresearchalsoprovidessomeguidance
on how to apply both approaches together (traditional
and quick), such as the standardization and the use of
templates and procedures in order to meet project
requirements. The results also show that commitment to
the role of project management is very important to
achieve successful results. The participation of senior
managementandprojectsponsorscontributedtothefinal
results.Theimplementationprovidedaholisticviewofthe
challenges found in the management of projects at small
companies that have specific constraints, such as
resources and knowledge about project management
concepts,thatimpactthewaytheymanagetheirprojects.
For these companies, regular iterations with their
customers contribute to add value and to better project
deliverables by anticipating project changes. Despite the
research limitations, both Questions were addressed, but
also need further empirical research. So some questions

forfutureresearchwouldbeasfollows:
a) Because resource and cost planning are notdealt with
by this system, how should resource planning and cost
planningisdealtwith?
b) How can plan and managing risk in innovative and
complexprojectsbekeptsimpleandpractical?
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TheProceedings
Recycled Polyurethane Foam as New Filler in Restoration Mortars

VojtchVclavk1,2Tom Dvorsk1,2Vojtech Dirner2 Jaromr Daxner3
JanValek4MilenaKunerov4
1
InstituteofEnvironmentalEngineering,FacultyofMiningandGeology,VSBTechnicalUniversityofOstrava,CzechRepublic
InstituteofCleanTechnologiesforMiningandUtilizationofRawMaterialsforEnergyUse,VSBTechnicalUniversityofOstrava,CzechRepublic
3
PorobetonOstravaa.s.,CzechRepublic
4
InstituteofPhysics,FacultyofMiningandGeology,VSBTechnicalUniversityofOstrava,CzechRepublic
2
ARTICLEINFO:
Abstract:
Recycling
PolyurethaneFoam
Filler
RestorationMortars
The article describesthe basic results of an experimental researchdealing withthe utilizationofrigid polyurethane foams,
theircrumblingusingknifemillsandsubsequentuseinrestorationmortarswiththermalinsulatingeffect.Thepaperpresents
theguidelineprescriptions,inwhichwewerelookingforanoptimalratioofbindingcomponentsdependingontheachieved
volumeweight,strengthcharacteristics,thermalconductivitycoefficientandcapillarywaterabsorption.
Citation:VclavkV,etal. RecycledPolyurethaneFoamasNewFillerinRestorationMortars,2ndInternationalConferenceManufacturingEngineering&Management2012,(2012),p.
204208,ISBN9788055312163
INTRODUCTION
flame retardants, water, and auxiliary expanding agents
[6].Fromtheviewpointofthemass,itishardorsemihard
macromolecular foam with a high proportion of closed
cells. The properties of rigid polyurethane foam change
withitsvolumeweight.SeeTable1.
Tab.1Propertiesofrigidpolyurethanefoamwithvolume
weightof3060kg/m3
Civil engineering has currently been experiencing a

substantial increase in the consumption of construction
materials.Thistrendiscausedbytheneedofthepeople
in the society to continuously expand their territory and
the building production must respond to this pressure.
Due to the increasing consumption of raw materials, we
are experiencing problems with their availability and,
ultimately, this trend may lead to the depletion of the
natural stocks. Fortunately, we can observe an increasing
utilisation of the secondary raw materials suitable for
buildingproduction.Itismainlytheuseofwasteproducts
frommetallurgical,mining,electricityindustryand,finally,
plastic industry materials. 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
blastfurnaceslagintheproductionofplainconcrete[1]or
the potential use of fly ash with a high content of
unburned coal in geopolymers with mechanical strength
ofupto55MPa[2].Wastefromplasticindustrymaterials,
such as crushed PET bottles or thermoplastic materials,
are used as fillers in concrete mixtures [3, 4], sometimes
even as an additive to asphalt [5]. There is an ongoing
verificationofthepossibleutilisationofrigidpolyurethane
foam in building materials, such as experimental studies
dealingwithpartialreplacementoflightfillerwithcrushed
rigid polyurethane foam for lightweight concrete [6].
Furtherresearchinthisareaisdevotedtotheproblemsof
the utilisation of rigid crushed polyurethane foam as the
dominant filler in thermal insulating mortars and light
concretes [8, 9]. Crushed polyurethane foam is also used
intheUSAasacomponentofthermallyinsulatingshutter
duringtheconstructionofconcretestructures.[7]
Property
Specificweight
Strengthincompression
Strengthintension
Strengthinbending
Shearingstrength
Emodule
Value
3060
0.20.4
0.350.85
0.30.7
0.150.3
5.12
CRUMBLINGOFRIGIDPOLYURETHANEFOAM
The crumbling technology opens new ways for the
recyclingofrigidpolyurethanefoamsandcomposites.The
crumblingofpolyurethanefoamscanbeperformedusing
conventional crushing and grinding methods in various
crushersandmills.Themostcommonlyusedprocessesof
crumblingare:
Grindingusingatwinrollmill;
Crushingusingaknifegrinder;
Grindingusingapelletmill;
Crushingusinganimpactcrusher;
Cryogenicgrinding.
A twinroll mill consists of at least one pair of contra
rotating rolls of different speeds. Due to the resulting
transverse forces, this mill is capable of crumbling rigid
polyurethane foam to a size smaller than 0.1 mm. The
crumbling process using this type of mill is more suitable
for flexible polyurethane foam [10, 11]. A knifegrinder is
used both for flexible and rigid polyurethane foam
grinding, and it is able to provide a particle size smaller
than0.25mm.Aknifegrinderischaracterizedbyitslarge
numberofstaticandrotatingknivesthatcutthecrushed
materialandfurthercrumbleitthroughspecialsieves[10].
A pellet mill consists of two or more metal rollers that
push the polyurethane foam through small holes in a
MATERIALS
RigidPolyurethaneFoam
Polyurethane foam is a macromolecular construction
material(thermoset),predominantlyorganicbased.Itisa
product of mutual exothermic reaction polyaddition of
diphenyldiisocyanateandmixturesofpolyhydricpolyether
and polyester alcohols, activators, catalysts, stabilizers,
204
Unit
kg/m3
N/mm2
N/mm2
N/mm2
N/mm2
N/mm2
V. Vclavk, et al.
plate. Depending on the type of crumbled foam and the

performance of the mill, the resulting product is either a
polyurethane powder or compact polyurethane pellets.
During the crumbling process, the material is exposed to
heat that depends on the roller speed, the material
thicknessandtheholediameter[10].
Crushing using an impact crusher is widely used for
crushingpolyurethaneproductsmanufacturesbytheRIM
technology Reaction Injection Moulding. Crushing takes
place in two steps. Firstly, the material is crumbled in a
knifegrindertoaparticlesizeofabout3mm,andthenit
goestotheimpactcrusher.Theresultingproductcontains
about 40% of particles smaller than 0.2 mm and 60% of
particles larger than 0.2 mm. The product is further
separatedandusedforvariousotherapplications[11].
Cryogenic grinding is suitable both for rigid and elastic
polyurethane foams. Due to overcooling, the conversion
ofworkintogrindingenergyislarger,thusincreasingthe
crusher efficiency. Liquid nitrogen, overcooled air (max
130 C) or a combination of both can be used as the
coolingmedium[10,11].
affectingtheconstructionchangedutilities,trafficloads,
pavement, basement rooms used for commercial
purposes, etc. 4 prescriptions with different ratios of
bonding components have been designed for
experimental mortar, see tab 3. Crushed polyurethane
foamwithagrainsizeof01mmwasusedasthefiller.
100
Totalsiftings(%ofweight)
80
EXPERIMENTALPART
BindersandAdditives
70
60
50
PURdust
40
30
0,5
20
PortlandcementCEMI42,5R(CementHranice,a.s.)was
used as the main binder in restoration mortar mixtures
with thermal insulating effect. Hydrate CL 90S (Kotou
tramberk,spol.sr.o.)andMetakaolnMefistoK05(esk
lupkov zvody a.s.) were used as well. Hostapur OSB SE
TyloseGmbHwasusedasanadditive,inordertoincrease
theporosityofrestorationmortarwiththermalinsulating
effect.
10
0
Siftingspercentagesummary[%]
0,063
0,125
0,25
0,5
1
2
4
6,9
6,9
8,4
27,1
99,8
100
100
0,5
Squarescreenholesize (mm)
Fig. 1 Graphic expression of curves illustrating sample
grainfineness
Tab.3Restorationmortarprescriptions
A grain size analysis of the sample of rigid polyurethane

foamwasperformedforthepurposeoftheexperimental
research. The grain size analyzes were conducted using
laboratorysievingmachinewithstandardsievesaccording
to SN EN 9331. The analysis of the particlesize took
advantageofthisrangeofsieves:0.063;0.125;0.25;0.5;
1; 2; 4 mm. The results of the particlesize analysis are
presentedinTable2andFigure1.
Tab.2Grainsizeanalysisofsample
Sievehole[mm]
0,1250,25
0,063
0,05
GroundRigidPolyurethaneFoam
Components
PURfr.0/1mm
CementCEMI42,5R
MetakaolnMefistoK05
HydrateCL90S
HostapurOSB
Water
Unit
(g)
(g)
(g)
(g)
(g)
(g)
P1
736
2431
24,3
1915
P2
736
1702
216
19,18
1604
P3
736
1621
810
24,3
2555
P4
736
810
1621
24,3
2715
RESTORATIONMORTARTESTS
The individual mixtures were prepared in a laboratory
mixer BSMI CM5AX from Betonsystem company. A
preciselyspecifiedamountofpolyurethanechippingswas
measured for each mixture, and the individual
components of binders, additives and water were
graduallyaddedtothemixtures.4setsoftestspecimens
with the dimensions of 40x40x160 mm were produced
from these experimental mixtures in order to determine
the volume weight of hardened mortar, the tensile
strength in bending, the strength of hardened mortar in
compression, the coefficient of capillary absorption of
water in hardened mortar. Test specimens with
dimensions of 140x40x160 mm were manufactured as
well,amountingtoonetestset,inordertodeterminethe
thermalconductivitycoefficient.
The graphic presentation of the grain size curve (see

Figure1)clearlyshowsthatthesiftingsofgrainsizeof0.6
mm represent 50% of the sample weight in case of this
polyurethanesample.Asampleofpolyurethanefoamhas
abalancedshareofparticlesinthegrainsizerangeof0.5
1mm.
Determination of volume weight of dry hardener

mortar
DESIGNEDRESTORATIONMORTARPRESCRIPTIONS
Restorationmortarsaredesignedforsurfacetreatmentof
damp and salinised masonry. Their main purpose is
moisture diversion, salt retention and protection of
masonry against the effects of water contained in the
masonry or external water that was brought in. They are
used both for indoor and outdoor plasters, 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 SN EN 101510

standard.3testspecimensweremanufacturedfromeach
experimental mixture. They were frames with the
dimensionsof40x40x160mm.Theframeswerekeptina
roomat22Cfor28daysandthenplacedinadryerata
temperatureof(605)C,untiltheweightofthetesting
specimen was stabilized. The frames were subsequently
weighed on scales and dry volume weight of hardened
mortar was calculated for each experimental mixture
205
1 2
90
V. Vclavk, et al.
according to formula (1). The results are presented in

Table4andFigure2.
,
[kg/m3]
(1)
bending.Thestrengthofhardenedmortarincompression
was determined using Formtest prfsysteme 2201 Mega
1020010device.Themeasurementresultsarepresented
intabularforminTable5aswellasgraphically(seeFigure
3).
Tab. 5 The results determining the strength of hardened
mortarintensioninbending
ms,dryweightoftheframedriedinadryer[kg]
Vsframevolume[m3]
Tab.4Resultsofdeterminationofvolumeweightofdried
hardenedmortar
Sample
marking
ms,dry
[kg]
Vs[m ]
Volumeweight
ofhardened
mortarpartial
[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
0,1543
0,1540
0,1546
0,1198
0,1185
0,1251
0,1494
0,1489
0,1507
0,1442
0,1444
0,1412
0,00026
0,00026
0,00026
0,00026
0,00026
0,00026
0,00026
0,00026
0,00026
0,00026
0,00026
0,00026
602,73
601,56
603,91
467,97
462,89
488,67
583,59
581,64
588,67
563,28
564,06
551,56
Volumeweight
ofhardened
mortar[kg/m3]
603
474
585
Sample
marking
Weight
[g]
Partialstrengthin
tensioninbending
[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
154,3
154
154,6
119,8
118,5
125,1
149,4
148,9
150,7
144,2
144,4
141,2
0,352
0,352
0,375
0,469
0,539
0,445
0,785
0,768
0,793
0,258
0,234
0,270
0,36
0,48
0,78
0,25
Tab. 6 The results determining the strength of hardened

mortarincompression
560
Fig. 2 Graphic expression of the results determining the

volumeweightofhardenedmortar
Determination of volume weight of dry hardener

mortar
Sample
marking
Strengthin
compressi
on1
[N/mm2]
Strengthin
compressi
on2
[N/mm2]
Partial
strengthin
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
0,675
0,688
0,656
0,725
0,863
0,844
1,518
1,590
1,542
0,344
0,375
0,356
0,706
0,669
0,750
0,688
0,906
0,719
1,560
1,612
1,565
0,369
0,381
0,363
0,691
0,678
0,703
0,706
0,884
0,781
1,539
1,601
1,553
0,356
0,378
0,359
Strengthin
compressio
n[N/mm2]
0,69
0,79
1,56
0,36
3testspecimenswereproducedfromeachmixture.They
were frames with the dimensions of 40x40x160 mm. The
framesintheformwerepackedinpolyethylenebagsand
storedinaroomattemperatureof22Cfor2days,after
that, the forms were dismantled, returned back to the
bags and stored for the following 5 days. After this time,
theframeswerestoredinalaboratoryenvironmentat22
C for 21 days. The frames were placed in the testing
machine Formtest prfsysteme 2201 Mega 1020010 on
supporting rolls, always in such a way so that the
compressionforceisperpendiculartothedirectionofthe
frame compaction. The machine applied balanced load,
free of shocks, until the frames broke. The measurement
resultsarepresentedingraphicandtabularform(seeFig.
5andFig3)

strengthofhardenedmortarintensioninbendingandin
compression
Determination of strength weight of hardened

mortarincompression
ItwasdeterminedaccordingtoSNEN101511standard.
The preparation of the specimens was carried out in the
samemannerasthepreparationoftestspecimensusedto
determine the strength of hardened mortar in tension in
Determination of strength weight of hardened

mortarincompression
Two test specimens with the dimensions of 40x40x160
mm were used to determine the coefficient of capillary
206
Strengthintension
inbending
[N/mm2]
V. Vclavk, et al.
The thermal conductivity coefficient was always

determined on one set of test specimens from each
experimental prescription. The actual measurement was
carriedoutusingISOMET2104device.Themeasurementis
based on the analysis of the thermal response of the
analysed material to heat flow impulses. 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. The evaluation of the
thermal conductivity and the volumetric heat capacity is
based on regularly collected temperature records as a
functionoftime,assumingthattheheatisspreadinginan
unrestricted environment. The measurement results are
presentedinTable.8andFigure5.
Tab. 8 Results determining the thermal conductivity
coefficientofrestorationmortar
absorption of water. The production of the test

specimens, including their conditioning, was identical to
the test specimens used for test s of the strength of
hardened mortar in compression and in tension in
bending. The test specimens were placed in a dryer at a
temperature of (60 5) C, prior to the test, in order to
stabilize the weight. The surface of the specimens was
subsequentlycoatedwithalayerofsealingcompoundof
beeswax along their long sides. The test specimens were
broken in two halves and placed with the fracture edge
downintoabowlofwater,withthewaterlevelof10mm.
Thetestwasterminatedafter90min,whentherewasan
apparent display of wet spots on the free surface of the
test specimens. The test specimens were later broken
longitudinally, and it was stated that they had been fully
saturatedwithwater.Bothpartswereweightedtogether
and the weight was recorded in table. 7 (value M3). The
capillary absorption coefficient was calculated using the
relation:
C=0.625.(M3M0)
[kg.m2]
where:
Ccoefficientofthecapillaryabsorptionofwaterforthe
individualtestspecimens[kg/m2];
M0weightofdriedtestspecimens[g];
M3weightofsoakedtestspecimensafter24h[g].
Tab. 7 Results determining the capillary absorption
coefficientofwaterinhardenedmortar
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]
0,356
0,368
0,475
0,461
0,780
0,791
0,242
0,253
Weight
M0[g]
Weight
M3[g]
Capillary
absorption
coefficient
C[kg/m2]
77,9
84,3
78,6
89,2
63,4
63,4
60,3
68,2
80,4
76,9
82,8
75,0
79,1
66,6
77,9
64,6
126,8
134,9
129,2
139,3
129,0
129,2
128,3
134,5
103,9
101,3
104,4
100,8
130,2
114,1
126,4
112,1
30,6
31,6
31,6
31,3
41,0
41,1
42,5
41,4
14,7
15,3
13,5
16,1
31,9
29,7
30,3
29,7
Average
capillary
absorption
coefficient
Cm[kg/m2]
31,3
Sample
marking
Thermalconductivity
coefficientpartial
[W/mK]
REC1_1
REC1_2
REC1_3
REC2_1
REC2_2
REC2_3
REC3_1
REC3_2
REC3_3
REC4_1
REC4_2
REC4_3
0,0936
0,0939
0,0937
0,1071
0,1074
0,1074
0,1104
0,1109
0,1105
0,0996
0,1000
0,0998
Thermal
conductivity
coefficient
[W/mK]
0,0937
0,1073
0,1106
0,0998
41,5
14,9
30,4

compression
CONCLUSIONS

compression
207
The presented results of the experimental research has

shownthatcrumbledrigidpolyurethanefoamwithagrain
sizeof01mmcanbeusedtoreplacethecurrentlyused
light fillers based on expanded volcanic glasses, such as
vermiculite, perlite, and obsidian in restoration mortars
with thermal insulating effect. The comparison of the
developed restoration mortar with the thermal insulating
effects based on polyurethane (Prescription 3) with
competing restoration mortars and restoration thermal
insulatingmortarsarepresentedinTable.9.
BasedonthepropertiespresentedinTable9,itisobvious
that the values of restoration mortars with thermal
insulating effect based on polyurethane (Prescription 3)
are comparable to those of the competing plasters. The
values of the strength in compression and the capillary
V. Vclavk, et al.
absorption coefficient meet the requirements of SN EN

requirements of restoration mortars, lies in the fact that
9981SpecificationsofmasonrymortarsPart1:Mortars
crumbledrigidpolyurethanefoamaftertheendofitslife
forinternalandexternalplasters.
cycle, which would otherwise be disposed of by
The new feature of restoration mortar with thermal
incinerationorlandfilling,istheonlyusedfiller.
insulating effect based on polyurethane, adhering to the
Tab.9Resultsdeterminingthethermalconductivitycoefficientofrestorationmortar
Name
PRESCRIPTION3
Restoration mortar
browncoatWTACEMIX
KVK Restoration mortar
browncoat0230K
SANIER
Porenausgleichsputz 208
HASIT
1,56
Thermal
conductivity
coefficient
[W/mK]
0,110
Capillary
absorption
coefficient
2
[kg/m ]
14,9
01,2
1,5to5
max.0,410
min.1,0
1250
02,5
1,5to5
max.0,420
min.1,0
12001400
03
1,5to5
0,390
>1,0
Volumeweightof
hardenedmortar
3
[kg/m ]
Grain
fineness
[mm]
Strengthin
compression
[N/mm2]
585
01
11001400
Acknowledgement
Thearticlewaselaboratedintheframework:
Project of Institute of Clean Technologies for Mining
and Utilization of Raw Materials for Energy Use,
registration no. ED2.1.00/03.0082 supported by the
Operational Program Research and Development for
Innovations financed by EU structural funds EU and
fromthestatebudgetoftheCzechRepublic;
Grants from the budget of MoravianSilesian region
No.0014/2012/RRC.
[6]
[7]
[8]
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[2] SVARLA, J., SISOL M., BOTULA J., KOLESAROVA M.,
KRINICKA I., The potential use of fly ash with a high
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123132.ISSN12149705.
[3] AKCAOZOGLU, S., ATIS, C. D., AKCAOZOGLU, K. An
investigation on the use of shredded waste PET
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[4] PANYAKAPO, P., PANYAKAPO, M. Reuse of
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Waste Management, 2008, vol. 28, no. 9, p. 1581
1588.
[5] AHMADINIA, E., ZARGAR, M., KARIM, M. R.,
ABDELAZIZ, M., SHAFIGH, P. Using waste plastic
[9]
[10]
[11]
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bottlesasadditiveforstonemasticasphalt.Materials
&Design,2011,vol.32,no.10,p.48444849.
MOUNANGA, P., GBONGBON, W., POULLAIN, P.,
TURCRY, P. Proportioning and characterization of
lightweight concrete mixtures made with rigid
polyurethane foam wastes. Cement and Concrete
Composites,2008,vol.30,no.9,p.806814.
BOSER, R., RAGSDALE,T.,DUVEL,Ch.Recycled Foam
and Cement Composites in Insulating Concrete
Forms.JournalofIndustrialTechnology,2002,vol.18,
no.3
VCLAVK, V., DVORSK, T., DIRNER, V., DAXNER, J.,
ASTN, M. Polyurethane foam as aggregate for
thermal insulating mortars and lightweight concrete.
TehnickiVjesnik.2012,vol.19,no.3,p.665672.ISSN
13303651
FRAJ,A.B.,KISMI,M.,MOUNANGA,P.Valorizationof
coarse rigid polyuretane foam waste in lightewight
aggregate concrete. Research Institute on Civil
Engineering and Mechanics. 2010, XXIV. Nr. 6, pp.
10691077.ISSN09500618.
ZEVENHOVEN, R. Treatment and disposal of
polyurethane wastes: options for recovery and
recycling, 2004th ed.; Helsinki University of
Technology Energy Engineering and Environmental
Protection:Espoo,2004.
ZIA, K. M., BHATTI, H. N., BHATTI, I. A. Methods for
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KeynoteLecture|
Requestedinvited|
"Anyonewhohasnevermadeamistakehasnevertriedanythingnew."
AlbertEinstein

TheProceedings
Developments in High Precision Metrology for Advanced

Manufacturing
NumanDurakbasa1JorgeBauer2GkcenBas3
1
DepartmentforInterchangeableManufacturingandIndustrialMetrologyandNanometrologyLaboratoryAuMattheInstituteforProductionEngineering
andLaserTechnology,TUWien,Karlsplatz13/3113,1040WienAustria
2
UTNFRBA/Argentina&AuMTUWien,Vienna,Austria,Email:
3
AuMTUWien,Email:goekcen.bas@mail.ift.tuwien.ac.at
ARTICLEINFO:
Abstract:
Precisionmetrology
Nanotechnology
Workpieceaccuracy
Industrialenvironment
AdvancedMultiFunctionsIntegrated
Industry
IntegratedManagement
The application of intelligent technologies also puts appropriate demands on production engineering in
modernindustrialenvironment.Asophisticatedhighaccuracymeasurementtechniquecanbeconsidered
asmostcrucialrequirementfortheproductionofindustrialgoodsandfortheproductionprocessesofhigh
quality. High accuracy workpieces are created nowadays by a large variety of advanced manufacturing
system and techniques. The problematic of the high accuracy of the work pieces in modern industrial
productiongainedinthelastyearsmoreandmoreimportancethroughconstantlyincreasingdemandson
the quality of the produced parts and quality of the production processes with higher efficiency and
effectiveness. On the other hand important charge of the environment, reduced availability of natural
resourcesandtheincreasinggrowthofwasteaswellasenergyuserequirenewconceptsandstrategiesto
recycletechnicalconsumergoodsastherearehouseholdinstruments,consumerelectronicsandpassenger
cars instead of land filling, burning or steel production a high potential of recycling is necessary. The
modern methods of QM, EM and EnM have been developed and refined in advanced manufacturing
systems and therefore there exists close interaction to intelligent metrology and industrial and
technologicaldevelopments.Metrologyisalsodevotedtothepracticeofmeasurementtasks.Onthebasis
of metrology essential measurement knowhow is developed and organisations are supplied with this
knowhow.
Citation:DurakbasaN,BauerJ,BasG. DevelopmentsinHighPrecisionMetrologyforAdvancedManufacturing,2ndInternationalConferenceManufacturingEngineering&Management
2012,(2012),p.210215,ISBN9788055312163
INTRODUCTION
Adequateknowledgeintheareasofintelligentmetrology
is important presuppositions to achieve waste free
production and low costs of manufacturing and accuracy
at the same time within the sophisticated production
systems.Thisisofextremeimportanceinpresenttimeof
worldwide international competition in industry and
productionengineeringandatthesametimeincreasingly
highercostsofenergyandrawmaterial.
As the tolerances of workpieces and their features
decrease, the interaction and correlation between the
dimensional tolerances and surface finish becomes
continuouslymoreimportant[6,7].Technicalsurfacesare
createdbyalargevarietyofmanufacturingprocesses.To
evaluate of surface finishes in the submicrometer and
nanometer level, very sophisticated instruments have
beendeveloped(seeFig.1)[8].
Measurement technique can be named as an "enabling

science" meaning that it is a science which makes other
developmentsfirstofallpossibleanditformsthebasisfor
inventions. 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. To
survive economically also at the today thoroughly usual
shorttermchangesofthestateofthemarketunderworld
wide competition, a high quality level of the prepared
products together with effectiveness and productivity
must be guaranteed, furthermore must be secured the
reliability at application and employment, for an
avoidanceofenergylossesmustbecarriedlikewiseasfor
thrifty consumption of raw materials care, and final are
aspectswithregardtoprotectionandconservationofthe
environmentofessentialmeaning.
During the last few decades there have been many
attempts to improve the quality of components and
productsbyindustryandasaconsequencetoreducethe
manufacturing defects that disrupt the manufacturing
process and become a severe cost burden to industry in
general. This cost burden is inevitably passed on the
consumers.
The modern methods of quality management [1], [2],
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
technologicaldevelopments.Metrologyisalsodevotedto
the practice of measurement tasks. On the basis of
metrologyessentialmeasurementknowhowisdeveloped
andorganisationsaresuppliedwiththisknowhow[5].
Fig.13Dinvestigationofananometerscaledsurfaceusing
anAFM
210
Developments in High Precision Metrology for Advanced Manufacturing
N. Durakbasa, J. Bauer, G. Bas
Iftheworkpiecegeometryofmachinedpartsisconsidered
as a whole there exist interactions between the different
featuresformingtheperipheryofthepart(Fig.2)[9].But
also within thesurface ofevery single feature there exist
interactions between geometrical deviations of different
kind and different order. If we take these deviations of
dimensions,roughness,formandpositioncollectivelythe
existing interactions are significant for the accuracy, high
quality and the functions of the parts that should be
accomplishedduringpracticalapplication.
In many countries, the abovementioned international

standards have been adopted also on a national level,
similar as the new international standards about quality
assurance,
quality
management,
environmental
managementandenergymanagement[1,2,3, 4].Inthis
respect the general term "Geometrical Product
SpecificationsandVerificationGPS"hasbecomerecently
wellknown for the area of mechanical engineering. It
defines on a technical drawing the shape (geometry),
dimensions and surface characteristics of the workpiece
under discussion. In this way the optimal function of the
respectivepartissupposedtobeguaranteedconsidering
certain
manufacturing
tolerances.
Nevertheless
workpieces will be produced, which do not fulfill these
requirements. Therefore workpieces are measured in
ordertocomparethemwiththespecifications.Thereisa
needtorelatebetweenactualworkpiecesand:
theworkpieceimaginedbythedesigner,
theworkpieceasmanufactured,
the knowledge about the workpiece as
measured.
In order to establish this relationship between design,
production and measurement and to clarify the mutual
importance,standardshavebeendevelopedintheareaof
GPS. Comprehensive knowledge in this area is an
important presupposition to achieve economic design,
construction,production,metrology,QM,EMandEnM.
Fig.2 Features forming the periphery of the part on ideal

modeland"SkinModel"ofaworkpiece[9]
INTELLIGENTDESIGNINTHEFRAMEOF:
GEOMETRICALPRODUCTSPECIFICATIONSAND
VERIFICATIONGPS
ADVANCEDPRECISIONMANUFACTURING
Developingfromtheneedformoreaccuratemachinesas
demandsgrewforexampleinthefieldsofIT,electronics,
fine mechanics and biotechnology, new methods of
fabrication came with different materials. Together with
theseapplicationstheneedcametomakesmallersensors
and actuators to enable the nonintrusive control of
instruments and machines. Also a special demand for
qualitymanagementisinthepointofviewinthisfield.
In engineering applications, 90 % of transducers are
concerned with the measurement of displacement,
position or their derivatives such as strain, pressure and
acceleration. This has resulted in a mechanical micro
world,whichhasemergedfromthetechnologydeveloped
for integrated circuits. Already many small mechanisms
are being made, including miniature motors of
submicrometerdimensions.Highlyreliableaccelerometers
arealreadyinuse.Thesedevicesarefabricatedonsilicon
substrates using extensions of such integrated circuit
manufacturing processes as photolithography, thin film
depositionandthelike.Micromotorsandarticulationsare
more ambitious but are developed in many parts of the
world.
The most important parameters in determining the
suitability of a technical part are its compatibility,
functionality, performance and corrosion resistance. The
precise assessment of wear, friction and miniaturization
demandscreationofnanometerscaledsurfacestructures,
surfaces with thin film deposition and ultra precision
surface treatment with the utilization of new
manufacturing and measurement instrumentation and
techniques. These include micro and nanofabrication of
surface patterns and topographies by the use of laser
machining, photolithographic techniques, and electron
beam and colloidal lithography to produce controlled
structuresontechnicalsurfacesinsizerangingfrom10nm
to100m.Atthetimebeing3Dsurfacemeasurementis
alreadyprovedtobeanimportanttoolinseveralareasof
surface analysis including wear, indentation, topography,
contactproblemsandfunctionalbehaviorofsurfaces(see
Fig.4,5).
Theproblematicofthehighaccuracyoftheworkpiecesin
modernindustrialproductiontechniquegainedinthelast
years more and more importance through constantly
increasingdemandsonthequalityoftheproducedparts.
The necessity faces to the additional outlay caused
through that in the entire manufacturing process, to
produce due to the worldwide competition fight's and it
pricepressure'sresultantfromthatmaximallyeconomical
and to strive for cost savings and efficiency increasing in
production.
Inthesameperiodtheneedsoftheindustryforultrahigh
precision engineering and workpieces with a surface
roughnesslessthanfewnanometerscallformeasurement
instrumentation that can be applied reliably in modern
production engineering, together with international
standards defining parameters and tolerances in the
nanometer scale in the frame of: Geometrical Product
SpecificationsandVerificationGPS(Fig.3)[10].
Fig.3Geometricaltolerancesandtolerancesofdimension
andgeometricalpropertiesofthesurface
The standards governing product design and
manufacturing have undergone basic international
harmonisation. Focal points of interest included;
workpiecemicrogeometry[11]andgeometricaldeviations
[12], as well as tolerancing principles such as;
Independency principle, Duality principle, Functional
control principle, Feature principle, General specification
principle, Responsibility principle etc., according to the
international standard [13], which applies to the
interpretationofGPSindicationsonalltypesofdrawings.
211
of high priority for mechanical engineering. This

fundamentalisbasedonthedevelopmentandapplication
of high precision manufacturing processes. Generally
dimensionalsurfacemeasurementtechniquehasthetask
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
oftensmallestorevencrystallinestructuresandmolecular
assignmentsareofspecialinterest.
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
capabilityinnanometrology(Fig.6).
Tab.1 Measurement techniques related to measuring

capability
Fig.4 Analysis of topographic structure on micro/nano

scalemachinedsurface[14]
Inthefirstplacetheextractionofhighqualityinformation
is a task of the measurement technology. High product
quality can be achieved only there, where the
measurementtechnologyisintegratedintotheproduction
event as far as possible strongly. On the other hand,
however, continuously new orders are made through
increasingqualityontothecapabilityofthemeasurement
technology. Quality protection and measurement
technology form an inseparable unit from that in the
processofmanufacture.Thetrendininstrumentationand
metrology was already developing in the electronics
industry where the drive was towards miniaturization for
higher packingdensities and faster switching. As a result,
highly controllable and stable processes such as
lithographywereintroduced.Thismeantaneedarosefor
the very accurate positioning of specimens. In turn this
resultedinaninterestinminiatureactuators,motorsand
accurate slideways for which new technologies have
required development. In particular new materials and
thin film research were preeminent. The appropriate
laboratory research provides the measurement bedrock
upon which modern society stands. Advanced products
require length measurements many times smaller than
humaneyescansee,aswellasprecisionmeasurementsof
voltage, frequency, velocity, pressure, radiation, and
temperature.
Limitsize
>10m
10m1m
1m100nm
100nm10nm
10nm1nm
1nm0,1nm
Fig.5 Measurement and analysis of surface texture in 2D

andsurfacetopographyin3D[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
ScanningStylusMicroscopy
NANOMETROLOGYINADVANCEDPRODUCTION
ENGINEERING
Toachievesurfacefinishesandparttolerancesinthesub
micrometer and nanometer level it is necessary to
incorporate very sophisticated instrumentation and
metrologyintothedesign.Thisdevelopmentstartedinthe
electronics industrybutmicro miniaturisationisalsonow
The dramatic improvement of ultraprecise manufacturing

machinesandtheinventionofnewproductiontechniques
like Focused Ion Beam Technology have made the
production of features and functional elements with
212
Measuringtechniques
CMM,mechanicalandpneumatic
comparators,opticalsystems
CMM,finemechanicalcomparators,
opticalandelectriccomparatorsspin
resonance
CMM,Electromagneticandelectrostatic
comparator,opticalinterferometer,
phasemicroscopes,darkfield
microscopes
CMM,Laserinterferometers,roughness
measuringdevices,fluorescence
microscope
Laserconfocalmicroscope,Xray
microanalyzer,SEM,SPM(STM,AFM),
electronandXraydiffractionsystem
micro and nanometer size possible and economically

reasonable.Inmetrology,thefurtherdevelopmentofthe
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
industrialnanometrologyinindustry.
Scanningtunnellingandatomicforcemicroscopesachieve
a ratio of resolution in lateral and in vertical direction of
nearly 1 showing an important advance over the
conventionalmethods.
The needs of the industry for ultrahigh precision
engineeringandworkpieceswithasurfaceroughnessless
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
suitableparameters,time,costingandtheguaranteeofa
predetermined process stability by means of measurable
andcorrelatedparameterscomeintofocus.
On basis of industry needs, the demands on industrial
nanometrology can be subdivided into three major
scientificattributes(Fig.7):
Reliability: Measurement results have to mirror the
real surface structure and statistic and systematic
errorsmaybereducedtoanabsoluteminimum.
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
shouldbecomparabletoo.
Reproduceability:Severalmeasurementsofthesame
sampleunderthesameconditionsmustresultinthe
same results. Changes in measurement conditions
must result in comprehensible changes in the
measuredparameters.
Fig.7DemandsonIndustrialMetrology
measurement technique is to be found in the real sense

hardly,butproductivepowerjoinedwithreliabilitystands
thoroughlyintheforeground.Criterionistheestablishing
of arbitrarily modelled productstogether with asupplier
customerrelationship. Completely actual transformations
canatfirstofallveryabstractlyappearingapplicationsas
necessarilyprove[16].
The various efficient tools, methods and techniques of
modernqualitymanagementcanbeutilisedhoweveralso
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
buildingenvironmentalmanagementpractice(ISO14001,
ISO 14004) as well as energy management systems (ISO
50001). This offers the opportunity to apply well known
systemsandwellknowntoolsinamodifiedformtosolve
a company's environmental and energy efficiency
problems[17].
Tomeethighleveldemandsbothfromindustrialandfrom
privatecustomersinthefuture,manufacturingenterprises
must be flexible and agile enough to respond quickly to
product demand changes. New models for alternative
configurationsoffutureindustrialorganisationsingeneral
which are usually applied and especially for small and
mediumsizedenterprises(SMEs)needtobeinvestigated.
Those new models can be developed on the basis of
intelligent production technologies and extensive use of
theinternet,ofdistributedcomputingenvironment(DCE)
technology, parallelprocessing computing and advanced
engineering data exchange techniques [18]. By these
meansglobalcompetitiveassociationsoffactoriesaswell
as of collaborating SMEs with intelligent, associative,
concurrent, interactive, modular, integrative, learning,
autonomous,selfoptimisingandselforganisingfunctions
are already under development and the world wide
applicationofsuchassociationsandcooperationswillbe
possibleinthenearfuture.
Intelligent measurement technique closes quality control
loops in production, in that an early recognising possible
reasonsforrejectionstogetherwithananalysisresultsthe
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
discoveringofmeaningfulstrategies[19,20]thereforethe
demanded workpiece accuracy can be achievedunder an
economicpointofview.
INTEGRATED MANAGEMENT FOR ADVANCED

MANUFACTURING
Fig.8ControlLoopsinIntelligentManufacturingSystems
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
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.Appropriatesolutionscanbefoundwiththe
help of flexible intelligent measuring cells and their
components[19].
To meet highlevel demands for comfortable daily life in
thefuture,manufacturingenterprisesmustbeflexibleand
agile enough to quickly respond to product demand
changes, and new models and configurations for future
manufacturing systems and enterprises need to be
investigated. "MultiFunctions 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 "MultiFunctional 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
distributedfactoriesonthebasisofadvancedengineering
data exchange techniques (Figure 9). Fu, S., and Raja, J.,
gave an example for an appropriate application for
engineeringmetrologyandICAQ[23].
Automatedmeasurementtechniqueclosesqualitycontrol
loops in production, in that an early recognising possible
reasonsforrejectionstogetherwithananalysisresultsthe
improvement of manufacturing processes and preventive
corrections can be introduced. For the draft and the
completionofworkpiecesexperimentalvaluesandexpert
knowledge of geometric deviations facilitate the
discovering of meaningful strategies [19] therefore the
demanded workpiece accuracy can be achievedunder an
economicpointofview.
Under this organizational production philosophy (MFIF)
described, we work on the research and development of
anautonomousmobilerobotforparticulartasksofquality
control and data collection for SPC (Statistical Process
Control).MFIMRMultifunctionIntelligentMeasureRobot
(Fig.9)isanautonomousunittobeabletomovebyitself
frommachinetomachine,takeaproductionpiece,check
themainvariablesandtransferthemeasureresultstothe
QAsystem.Thisunitiscomposedbyaroboticarmwithsix
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
positionanddotheQAplannedtasks.TheMFIMRRobot
is equipped with its own intelligence that gives it work
autonomy, link with WIFI and Internet, to enable the
telepresence and teleoperation from a local or global
position.
goal which at least can be realised partly. Improvement

andoptimizationofproductionprocessesispossiblebased
on the supervision of quality in the process chain as well
as by means of knowledge and learning management
systemsandselflearningsystems.Thismethodpermitsto
learn stepwise from deviations and to improve the used
processescontinuously.
IntheICAQsystemFuzzyLogicwillbeappliedforQuality
Function Deployment (QFD) and for monitoring and
forecastingofmaintenanceofmeasuringinstruments[20],
further on for CAD and for an expert system for
tolerancing and quality planning. Through the application
offuzzylogicattheinterfacebetweenmanufacturingand
metrology can be performed on the one hand evaluation
and trend analysis of measuring data help to achieve
wastefreeproduction,ontheotherhandfailureanalysis,
which is the basis for decisions to monitor production
equipment.
Intelligent coordinate metrology is a very important tool
tosolvevariousproblemsofproductionmetrologyandto
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 [14]. This way of metrology is
the uptodate measuring method for complex
dimensionalandgeometricalmeasuringproblems.
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.Thisisinordertoobtainthedigitalmodelofthe
product and to modify it in ICAD system and then to
create a new modified surface model and CNC programs
formanufacturingofthefinalproductbymachinecenter
in the workshop. An important development as far as
workpiece metrology is concerned is the big general
advanceofcoordinatemetrologywhichalsohappenedin
thesameperiodoftimeascomputeraidedmetrologyand
GPS in general. In a system or compound of SMEs as
described above, CNCcontrolled intelligent CMMs are
connected by using networks with design and
manufacturing.Thegoalistomutuallyusethedatastored
in ICAD, ICAM and ICAQ systems, and to realise data
parallelprocessing.
New breakthroughs by the instrumentations have been
made in recent years, to establish hightech instruments
which can acquire a 3D surface structure of the precisely
machined surfaces to fulfill the requirements for the
applicationinindustrialenvironment[21].
Thesemeasuringtechniquesaretypicallyusedforsurface
characterization. For 3D measurements it is often more
advantageoustouseaCMM.SuchNanoCMMshavebeen
recentlyintroducedachievinganuncertaintyof100nmor
better and enabling threedimensional measurements as
wellasscanningofhighprecisionparts.
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
resolutionslessthan50nminindustryandlessthan1nm
innationalmetrologyinstitutesaredesiredtoday.
INTEGRATED MANAGEMENT FOR ADVANCED

MANUFACTURING
Theautomationofmeasurementtechniqueisparticularly
under the point of view of the productive power of
Fig.9MultifunctionIntelligentMeasurementRobot.
214
CONCLUSIONANDFINALREMARKS
In modern manufacturing systems there exist close
interactions between intelligent design, intelligent
metrologyandindustrialandtechnologicaldevelopments.
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
scanningofhighprecisionparts.SCM,AFM,STM,Scanning
Probe Microscopy (SPM) and NanoCMM are such
advancedmeasurementtechnologies.Attheatomiclevel
metrology and fabrication are closely related. STM has
madepossiblethefirststepsofatommanipulationwhich
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
playabasicroletoensuretherealisationoftheconcept,
through the advanced manufacturing systems based on
intelligent production metrology in the system to create,
torealizeandtopresentthefeatures,suchasconcurrent,
interactive, modular, integrative, learning, autonomous,
self optimising and self organising functions. It is correct
thatintegratedmanagementismuchmorethanpractical
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
intelligentmeasurements.
[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
Requirementswithguidanceforuse
[5] Osanna, P.H.: Intelligent production metrology A
powerfulltoolforintelligentmanufacturinge&i112
(1997),H.4,pp.162168.
[6] Tabenkin,A.EffectsofFormandFinishonTolerances
QualityVol.9,1993
[7] Osanna P. H., Durakbasa M.N., Kruter L.,
"IndustrialMetrology
and
Interchangeable
Manufacturing
under
the
Viewpoint
of
Nanotechnology and Nanometrology, Bulgarian
Academy of Sciences, Problems of Engineering
CyberneticsandRobotics,vol.59,2008,pp.6073.
[8] D. Whitehouse, "Comparison between stylus and
opticalmethodsformeasuringsurfaces",AnnalsCIRP
,vol.37,no.2,1988,pp.649653.
[9] M.N.Durakbasa,A.AfjehiSadat,N.NomakAkdogan:
?"Dimensional and Geometrical Measurements and
Interpretation of Measuring Results on the Basis of
the SkinModel"; ?Measurement Science Review, 1
(2001),1;S.8992.
[10] ISO TR 14638: Geometrical product specification
(GPS)Masterplan
[11] EN ISO 4287:2009, Geometrical Product
Specifications(GPS)Surfacetexture:Profilemethod
[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
Tolerancesofform,orientation,locationandrunout
Amendment1:Representationofspecificationsinthe
formofa3Dmodel.
EN ISO 8015 2011: Geometrical product
specifications (GPS) Fundamentals Concepts,
principlesandrules.
Keyence: Laser Scanning Microscope Guide
(CompleteEdition).www.keyence.com
Whitehouse D.J., 2003, "Handbook of Surface and
Nanometrology",London,InstituteofPhysics.
Osanna,P.H.,M.N.Durakbasa,J.M.Bauer,L.Kruter:
"Global International Cooperation of Collaborating
SmallandMediumSizedEnterprisestoAchieveTotal
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
8670835948;S.16
Osanna, P.H., Durakbasa, N.M., AfjehiSadat, A.: Life
CycleAssessmentandModernMetrologyforQuality
Management Systems in Industry. International
Journal for Production Engineering and Computers,
Production Engineering Department, Belgrade, SCG,
Vol.6,No.7,2004,YUISSN14505096,pp.29/38.
Osanna, P.H., Durakbasa, N.M., Tahirova, H.S.:
IntelligentFlexibleDisassemblyandRecyclingofUsed
Products to Support Total Quality Management and
Sustainability in European Industry. Proceedings of
3rd International Working Conference "Total Quality
ManagementAdvancedandIntelligentApproaches"
(Editor: V.D. Majstorovic), Belgrade, SCG, MayJune
2005,ISBN8670835142,pp.1/4.
Osanna,P.H.,Durakbasa,N.M.,Oberlaender,R.:Low
Cost Solutions for Quality Management in Flexible
AutomatedProductionSystems.
Durakbasa, N. M., Osanna, P. H.: Lageabweichungen
bestimmen
die
Werkstckgenauigkeit.
wt
Werkstattstechnik79(1989),N.3,141/145.
Durakbasa M.N., Osanna P.H., Demircioglu P., The
Factors Affecting Surface Roughness Measurements
oftheMachinedFlatandSphericalSurfaceStructures
The Geometry and the Precision of the Surface,
Measurement44,10,pp.19861999,2011.
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,
HersheyPAUSA,2009,ISBN:9781605668925,S.
175186.
Fu, S., Raja, J., Slawi?ski, E., Mut V., Control for
Teleoperation of Mobile Robots, Proceeding of the
3rdInternationalConferenceonIntegratedModeling
and Analysis in Applied Control and Automation,
IMAACA 2007, vol. 1, pp. 1722, ISBN: 9782
952071277,(2007).
Conference Sponsors |
in alphabetical order|
1st Presov tool making company, Ltd., Preov, Slovak Republic
A.G.E.S. Ltd., Olcnava, Slovak Republic
AVON, Ltd., Bratislava, Slovak Republic
DRC, Ltd., Preov, Slovak Republic
SPINEA Solution for Precision, Preov, Slovak Republic
VIA MAGNA, Preov, Slovak Republic
WELDEX, Ltd., Preov, Slovak Republic
If A is success in life, then A = x + y + z. Work is x, fair-play is y and z is keeping your mouth shut.
Albert Einstein
Catalogue
Katalog
I/ 2009
DriveSpin
DriveSpin
D
D r i vre Sipv
ine S p i n
SPINEA, s.r.o. ist eine sich entwickelnde
Maschinenbaugesellschaft, die sich an die
Entwicklung und Produktion von hochprzisen
Getrieben (TwinSpin) und Aktuator (DriveSpin)
orientiert. Wir wrden Ihnen gerne eine neue
Entwicklungslinie DriveSpin prsentieren. Es
handelt sich um eine hochprzise und kompakte
Einheit die von einem Getriebe und einem
Servomotor besteht.
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 berall wo man

eine przise Positionierung verlangt benutzt,
z.B.:
Roboter und Automatisierung
Werkzeugmaschinen
Textilmaschinen
Handhabungs- und Transportsysteme
Navigationssysteme
Medizinische Einrichtung
Glasbearbeitungsmaschinen
Marinenindustrie...
Specifications in this catalogue are subject to

change for improvement without prior notice.
Edition I / 2009
Modifikationen der in diesem Katalog angegebenen

Daten aufgrund technischen Fortschritts
behalten wir uns ohne vorherige Bekanntmachung
vor. Ausgabe I / 2009
DriveSpin
SPINEA, s.r.o. is rapidly growing Engineering

Company, which deals with development and
production of high precision bearing reducers
(TwinSpin) and actuators (DriveSpin). We would
like to present you a new progress line
DriveSpin. It is a high precision compact unit that
consists from bearing reducer and servomotor.
DriveSpin
Main characteristics of DriveSpin:
DriveSpin - wichtigste Vorteile:
- Compact design
- Zero backlash
- High dynamic performance
- High torsional and tillting stiffness
- Small size, low mass
- Simple installation
- High load capacity of radial-axial output bearing
- Maintenance free
Applications:
- Robotics: 6-axis robots, gantry robots and
manipulators
- Machine: CNC machine, grinding machine, lathe
machine
- Special machine: bending machine
- Medicine equipment
- Aerospace applications
- Flight simulators
- Defense industry
- Semiconductor industry
- Radar and monitoring systems
kompaktes Design
kein Umkehrspiel
hohe dynamische Leistungen
hohe Kipp- und Verdrehsteifigkeit
kompakte Abmessungen
einfache Installation
hohe Belastbarkeit des Radial-AxialRollenlagers
- wartungsfrei
Anwendungsbeispiele:
- Robotertechnik: 6-Achsen Roboter,
Gantryroboter, Manipulatoren
- CNC Werkzeugmaschinen (drehen, frsen,
schleifen usw.)
- Biegmaschinen
- Medizinische Einrichtungen
- Flugzeugindustrie
- Rstungsindustrie
- Halbleiterindustrie
- Radar- und Navigationssysteme
SPINEA, s.r.o.
Okrajov 33
080 05 Preov
Slovakia
Tel.:
+421 51 / 7700155
+421 51 / 7700156
+421 51 / 7756965
+421 51 / 7700162
Fax:
+421 51 / 7700154
+421 51 / 7482080
E-mail: info@spinea.sk
Web :
www.spinea.sk
1.PN
moulds & tools
st
1 Presov tool making company Ltd.
We mouldingYour ideas....
1. preovsk nstrojren, spol. s r.o.
Company profile
<
Profile
1. preovsk nstrojre spol, s .r.o. is a
private company, the main production
programme of which is represented by the
production of tools injection moulds for
thermoplastics and dies shear and bending
tools.
In May 1999 the company was registered in
the Commercial register of District Court in
Presov (Section Sro, Insert Nr. 11648/P) as an
independent company.
Using its more than 50 year tradition in the
production of special tooling, we provide our
customers with seriousness at collaboration,
professionalism of order solving and
accommodating production terms with
support by modern technologies, software
equipment and quality working team.
The company employs 56 employees and the
estimated turnover in 2007 is 58 mil. Sk
(1.750.000 EUR).
Company vision:
"Achievement of prominent place on the Slovak
market of producers of tooling".
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,
electrotechnic and automotive industries.
Confirming of the company qualities in its
=
business and character of its activities by
certifying it to ISO/TS 16949.
Investing
=
<
History
The history of the company dates back to the year 1947, when the development started in Presov of the
concern company KIK. 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.
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.
preovsk nstrojre, s.r.o.
1.PN
moulds & tools
<
Development of turnover and employment
4
year 2000
Diagram prezentation of the development of economical indicators
=
number of employees: 68
=
turnover: 22 mil. Sk
=
product./empl.: 324 thous. Sk
4
year 2001
=
=
=
4
year 2002
=
=
=
4
year 2003
=
=
turnover: 33,5 mil. Sk
=
4
year 2004
=
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
=
number of employees
turnover
productivity per employee
=
4
year 2005
year 2006
4
=
=
=
=
=
product./empl.: 1.018 thous. Sk

=
<
Quality
In the long term, the company has the
procedures for the quality achievement
implemented in the time when the tool
making division, as the part of the
company KRIZIK a.s., was
certifies by RV TUV.
The company has proudly
been ISO 9001 certified since
January 2004.
The in process, and
naturally also final inspection
are implemented for the
validation of tools and
pressings. The incoming
inspection is realized by
means of certificates of
purchased materials.
1.PN
moulds & tools
Production
<
Structure of the production - production programme
Injection moulds for thermoplastic materials represent approximately 85 % of the production. The
limiting dimensions of tooling currently are 1100x800mm and the weight 5 T.
Characteristics of the production
Production programme:
4%
pressure die casting of thermoplastic 3% 5% 3%

materials, 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, control fixtures,
=
Other
gauges, templates and others...
moulds for
=
<
Complex offer
"We provide a complete offer not only for the production of tooling, but also for the subsequent
operation thereof in terms of securing of the serial production of parts....".
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, production of tooling necessary for the serial
production and finally its realization as such, the 1. preovsk
nstrojre and LPH Vranov
n/T, s.r.o. 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, but
LPH Vranov n/T disponuje
also for the subsequent
vstrekovacmi lismi s uzatvracou silou
operating
in terms of
v rozsahu 25 - 1000Ton.
securing the serial
production of parts. It is of course possible to interpret this
collaboration in the opposite order production of plastic parts
with securing of the production of tooling.
The common participation of these parties ended in property
connection in December 2001.
www.lph.sk
1.PN
moulds & tools
email:lph@lph.sk
Orientcia spolonosti je zameran

nielen na lisovanie dielcov, ale aj na
montne a in dodaton opercie.
<
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
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.
CAD/CAM
Four installations of Pro/Engineer are the basis
of the software equipment of design department.
Other programmes are those for NC code generation for 3D or 2D machining for CNC
machining centres, for the definition of course of the electroerosion cutting machines and
mould flow simulation.
Data compatibility / supported formats:
3D:
prt, exp, iges, step, vda,
2D: dwg, dxf
1.PN
moulds & tools
<
Machinery equipment
"The priority goal of the
company is to invest into
moderniza-tion, 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 7.10.5
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. preovsk nstrojre are applied,
directly by our customers or indirectly, in the assemblies and on assembly lines of several
companies, i.e.:
1.PN
moulds & tools
Contact
1. preovsk nstrojre, spol. s r.o.
ubochnianska 2407/2
080 06 PREOV-UBOTICE
SLOVENSK REPUBLIKA
tel:
Fax:
Mob.
Email:
www:
+421.51.7485051
+421.51.7485050
+421.905.255230
info@1pn.sk
http://www.1pn.sk
<
Contact persons:
Function
Name
Phone
email
Company director
Quality
Production logistic
Production
Design
Technology
Economy
Human resources
C.E.O.
tefan Dzurenda
Vladimr Benko
Ing. Vladimr Slovk
Milan Leko
Ing. Marin eledinsk
Ing. Jan Host
udmila Baranov
Mria Kmecov
tefan Dzurenda
+421.51.7485052
+421.51.7485054
+421.51.7485061
+421.51.7485053
+421.51.7485056
+421.51.7485057
+421.51.7485055
+421.51.7485055
+421.51.7485052
dzurenda@1pn.sk
benko@1pn.sk
slovak@1pn.sk
lesko@1pn.sk
celedinsky@1pn.sk
host@1pn.sk
baranova@1pn.sk
kmecova@1pn.sk
dzurenda@1pn.sk
<
Location map:
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Title: ManufacturingEngineeringandManagement
Editors: HLOCHSergej
HUSRJozef
KNAPKOVLucia
LAZRIvan
LayoutandDesign: HLOCHSergej,HUSRJozef
CoverDesign: HUSRJozef
Publisher: FVTTUinKoicewithaseatinPreov
Print: STEVEPRESS,Ltd.,Preov
2012
ISBN: 9788055312163
Dear Participants, Dear Colleagues, Dear friends

my great friend Prof. Draan Kozak, wrote me in one e-mail Democracy lies on
the conscious individuals who are living for innovations in science, especially in
gaining new experience based on experiments. Thank you my Friend for your big
words.
When examining the world around either at home or work, when travelling and
entertaining oneself or working results of the work of anonymous scientists and
engineers are being used. Science, technology and management surprisingly
bring new inventions, breakthroughs, applications and permeate in other spheres
of human life. 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. Many times the reason rests in waving the advances or inventions
aside or in becoming frightened of them. In fact, science, research and related
reshaping of natural or artificial substance-material through technologies
significantly affect society development.
Technologies and engineering are overcoming distances yet absence of certain
closeness to the man and chiefly among people is apparent. 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. To what extent is reality accessible? The
question should be raised other way. Why? Because reality includes both objects
and events occurring beyond the human cognition, perception, imagination,
fantasy. 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. However, certain space exists between the borders of
cognition and fantasy. It is the space for ideas within the frame of which the most
significant moments, milestones of human life commence. In point of causality it is
the area of undefined reasons and interactions many times vaguely described by
terms of destiny or accident. 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.
Human mind, fortunately, is not partial to mess. For the present the only
working means, kind of battery(or light) in the space of unknown matters is
exploration magnifying notional radius of cognition. Inter alia, science means
studying and knowing (learning). Technologies mean knowing how to do.
Management means how to organize. Jointly they are included among the
strongest forces helping get the ideas dressed into reality which change the way
of life, habits and view over the world of every society inclusive of ours as well.
Specifically, technologies represent processes which through the explicit or
implicit research and development stage, i.e. by application of scientific
knowledge not only do allow commercial production of goods and services.
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. Concern
for the man himself and his fate must always form the chief interest of all technical
endeavours ... Yes, without the unsolved issues and issues not being solved one
would possess nothing. Following pages deal with the issues of our ancestors
and consequently with the ones is having occurred in the course of experimental
work, Your work...
On behalf of the
organizing
committee
Conference financially
supported by:
AVON s.r.o., AGES s.r.o.,
DRC s.r.o., Weldex s.r.o.,
Spinea s.r.o. Preov, 1. preovsk
nstrojre s.r.o., VIA MAGNA
Topvar Brewery - ari Brewery
ISBN 978-80-553-1216-3

2012 FV ICMEM Cover PDF

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MANUFACTURING ENGINEERING AND MANAGEMENT

Proceedings of 2nd International Conference on

included among the strongest forces helping get the ideas

my great friend Prof. Draan

But as Albert Einstein said: It is not enough that you should

Technologies and engineering are overcoming distances yet

This year, ICMEM Organizing Committee received more than

Human mind, fortunately, is not partial to mess. For the

At last I would like to say big THANK YOU, to my friend prof.

One of the ideas of the cooperation between the city of

This Conference has encouraged us to see the future of the

At the present time, the City of Preov makes an effort to

Inaugurated in 2010, the International Scientific Conference Manufacturing Engineering and

Contents lists available at www.icmem.tk

Manufacturing Engineering & Management

Application of Weld Thermal Cycle Simulator in Manufacturing

Thermal cycle simulation method is an experimental

Fig. 3 Specimen for thermal cycle simulation by the

Application of Weld Thermal Cycle Simulator in Manufacturing Engineering

Fig. 4 Execution unit on simulator of thermal cycle type

Fig. 5 Position of dilatometer, thermocouple and gas

Application of Weld Thermal Cycle Simulator in Manufacturing Engineering

Therefore, in that case it is possible to compare cooling

Fig. 7b Double weld thermal cycle simulation;

Application of Weld Thermal Cycle Simulator in Manufacturing Engineering

Fig. 12 Microstructure of base material (light microscope

Fig. 11 Basics of welding technology of T/P91 to T/P91;

Fig. 9 TTT diagram of P91 steel with chemical

Application of Weld Thermal Cycle Simulator in Manufacturing Engineering

Fig. 14 Results of Vickers hardness measurement before

Contents lists available at www.icmem.tk

Manufacturing Engineering & Management

Selection of Appropriate Moving Heat Source Shape of Submerged

Several critical input variables e.g. current, voltage,

by infrared thermometers (OMEGA SCOPE OS524E,

advantages.Researchers [11,25,26] investigated analytical

Fig. 1 Representation of axes and identification of few

The welding parameters were recorded during actual

Material Properties: In the present analysis, CMn mils

MEMCO semi automatic welding machine with constant

Tab. 3 Variation of thermo mechanical properties with

So ,heat source shape for this study was assumed as an

Assumption made in thermal model: In developing the

Fig.3 Comparison of ellipse (

1shapes.It was found from

due to the point heat source dQ at time t ;( x, y, z) =

solution for the instant point source that satisfied the

Values A, B, C can be measured from weld bead

Where =thermal diffusivity, c_p=specific heat, =mass

Finally, by assuming the body was initially at the

Then the temperature induced by the oval heat source

Ix has been calculated by applying numerical method

If we assume that the heat has been continuously

Assuming that heat has been continuously generated at

Induced Temperature Field: Heat conduction in a

Comparison of measured and estimated

Calculation of a,b,c have been done with the help of

So, equation can be written in this way when convective

Comparison of measured and estimated

Let equation of oval Shape heat affected zone boundary

Tab.8 Calculated values of (1

Relation with temperature