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P. Folęga and G. Siwiec

Numerical Analysis of Selected Materials for Flexsplines

The computer analysis of the influence of flexspline materials at the strength of the flexspline was performed for two and three dimensional models using the finite element method and MSC Patran/Nastran software. Calculations were conducted in two steps. The first one concerns two dimensional models on the contact between the flexspline and the wave generator. The second concerns three dimensional models of flexspline. The application of steel and steel-composite materials as material of the flexspline in harmonic drive was analysed. In calculations were used two types of composites with an epoxy resin, reinforced by the carbon-fiber or the glass-fiber. The preliminary study of stresses for the developed models was made. The steel-composite hybrid flexspline as compared to conventional steel flexspline showed a decrease of maximum stress in the analyzed dangerous cross-sections. Shapes and the frequency of vibration of the flexsplines were also calculated. The impact of stacking fiber angle on the frequency of vibration in the tested flexsplines is negligible.

Open access

R. Burdzik, P. Folęga, B. Łazarz, Z. Stanik and J. Warczek

The study discussed in the paper consisted in testing the impact of surface layer parameters on wear intensity of friction pair components. The study was conducted having taken additional operational factors into consideration, namely the friction conditions (presence of lubricant) and the value of loads affecting the contact zone of the samples being tested. The study constituted laboratory tests of wear and were conducted by means of a T-01M type laboratory test stand used to experimentally analyse frictional cooperation of various materials used in structural components of motor vehicles. The friction pairs examined were previously operating in a pin-on-disk system under various conditions. The materials of the friction pairs tested at the stand were subjected to heat treatment and chemical processing in order to attain specific parameters of their surface layers. The studies conducted enabled determination of the abrasive wear values for the material samples tested having entailed the surface layer parameters and the factors related to operation of actual structural components used in automotive engineering. An additional advantage of the studies conducted was the possibility to establish actual coefficients of friction occurring in specific friction pairs. Establishing the actual values of friction coefficients for the materials of friction pairs under specific conditions and having taken the impact of the surface layer parameters into consideration enabled identification of the reasons for excessive surface wear. Hence a reference can be made between the stationary tests undertaken and actual components cooperating with one another in kinematic pairs of machines. The utilitarian premise resulting from the studies conducted is the necessity of paying particular attention to surface layer parameters while designing friction pairs for machines.

Open access

R. Burdzik, Ł. Konieczny, Z. Stanik, P. Folęga, A. Smalcerz and A. Lisiecki

Abstract

The paper provides an analysis of the reasons for excessive wear of the camshafts system components based on models developed to describe the impact of selected material, technological and operational factors. The subject of the research was wear of camshaft cams studied in accordance with results of operation tests. Based on the said tests, the dependence of wear intensity of cams from their angular position was established. The respective calculation results enabled the function of cam fallibility to be determined.

Open access

A.M. Wittek, R. Burdzik, P. Folęga, Ł. Konieczny and B. Łazarz

The paper presented results of the research on process of production of highly important element of passenger car. The main object of the research was influence of production process and material factors on fatigue strength of tubular stabilizer bar. The scope of the research included the stabilizer bar hot bent at the bending table, hardened in oil and tempered. The bending radii I, II and III were metalographically tested. The stabilizer bar was also subjected to fatigue tests. For analysis purpose the finite element method (FEM) calculation have been conducted. The analysis of relationship of outer diameter to wall thickness is very important. The analysed bar has broken early. The paper presents the reasons for premature failure of the tubular stabilizer bar.

Open access

A. Lisiecki, R. Burdzik, G. Siwiec, Ł. Konieczny, J. Warczek, P. Folęga and B. Oleksiak

Autogenous laser welding of 0.8 mm thick butt joints of car body electro-galvanized steel sheet DC04 was investigated. The Yb:YAG disk laser TruDisk 3302 with the beam spot diameter of 200 μm was used. The effect of laser welding parameters and technological conditions on weld shape, penetration depth, process stability, microstructure and mechanical performance was determined. It was found that the laser beam spot focused on the top surface of a butt joint tends to pass through the gap, especially in the low range of heat input and high welding speed. All test welds were welded at a keyhole mode, and the weld metal was free of porosity. Thus, the keyhole laser welding of zinc coated steel sheets in butt configuration provides excellent conditions to escape for zinc vapours, with no risk of porosity. Microstructure, microhardness and mechanical performance of the butt joints depend on laser welding conditions thus cooling rate and cooling times. The shortest cooling time t8/5 was calculated for 0.29 s.

Open access

R. Burdzik, A. Lisiecki, J. Warczek, Ł. Konieczny, P. Folęga, A. Szkliniarz and G. Siwiec

The article addresses a method proposed for comprehensive research of vibration properties dedicated to new structural materials. The method in question comprises three-stage studies, thus enabling the related costs to be reduced on each stage of the process. Subjects of identification and assessment are both the properties and the material structure as well as numerically determined dynamic characteristics and actual vibration characteristics of materials. The article provides preliminary research results obtained for Cu-2Ti-1Co and Cu-6Ti-1Co alloys, the mechanical properties of which are very prospective. An additional advantage of the method proposed is the capability of identifying alloy types by application of non-destructive vibratory methods.