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Manufacturing of a connecting pin by cold forming
Koumar, František ; Peterková, Eva (referee) ; Jopek, Miroslav (advisor)
The diploma thesis is focused on the optimization of the production of a rotary connecting pin, produced by bulk cold forming with a focus on upsetting and forward and backward extrusion. The resulting pin will be made of 1.4511 steel. From the three proposed variants of production processes, the optimal variant for four forming operations was selected. Extrusion tools are made of tool steel 19 830. A numerical simulation was performed to verify the suitability of the sequence of the selected variant. The size of the production batch is set at 700,000 pieces / year. In the technical and economic evaluation, the calculated production price of 1 piece of part was coMPared between machining and volume forming, at which the production costs amount to CZK 6,64. The return on this method, with an assumed profitability of 10%, was found for 568 182 pieces produced.
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Manufacturing of the water siphon by sheet metal forming
Toufar, Jan ; Lidmila, Zdeněk (referee) ; Jopek, Miroslav (advisor)
The thesis presents a design for the manufacturing of a foul air trap made of chromium-nickel austenitic stainless steel resistant to corrosion 1.4301. In regards to the rotationally symmetrical shape of the air trap, the most fitting technology for manufacturing was deep drawing without thinning of the side and for the preparation of the blank shearing. The selected method of drawing, results in the necessity to utilize a triple action press, which allows for the optimal connection of all selected technologies into one combined tool. All technological calculations were determined and examined. Based on these calculations, a tool was designed. In this tool, the component is assembled out of a coil in three operations of one stroke. The selected machine for production is the press Dieffenbacher PO 250.
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Bulk forming technology of piston of disk brake
Kiza, Jakub ; Jopek, Miroslav (referee) ; Forejt, Milan (advisor)
The master’s thesis presents a proposal for the manufacturing technology of a disk brake piston made of material ČSN 41 2010 for a car brake caliper. Method of cold volume forming was chosen due to the production requirement of 200 000 parts per year, convenient axisymmetric shape of the part and required size tolerance. Based on study of chosen technology, production technique, which contains calibration and backward extrusion, was designed. Technological computations and optimalization of tool dimensions were done for the chosen production technique. The manufacturability of the part was verified by numerical simulation in Simufact Forming software. Because of unavailability of automatic cold forming machine designed for bigger sized parts on the market, the forming process is done by two forming tools with use of INWORK 700 hydraulic press. For the selected profit of 20 % the price for the part was set at 26,8 Kč. The turning point was determined as 52 745 pieces.
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Simulation of machining operation using explicit FEM
Gabriš, Andrej ; Jopek, Miroslav (referee) ; Zouhar, Jan (advisor)
This diploma thesis deals with the analysis of machining of aluminum alloy with the designation EN AW-6061 T6511 according to ČSN EN 573-3. The first part of the thesis provides a theoretical introduction to the measurement of cutting forces with application of different approaches. The thesis further analyzes the topic of quasi-static and dynamic material behavior and its description by Johnson-Cook plasticity material model. The last part deals with parsing of mathematical approaches in finite element method (FEM) and the simulation of machining under the chosen cutting conditions.
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Manufacturing of the Wall Bracket
Fridrich, Ladislav ; Jopek, Miroslav (referee) ; Řiháček, Jan (advisor)
The bachelor's thesis deals with a suitable design of production technology for a wall bracket, which will serve as a speaker positioning system. The part is made of non-alloy structural steel S 235JR with a thickness of 3 mm. The production series is set at 200,000 pieces per year. After evaluating the production possibilities, the technology of bending and progressive cutting is chosen, which are combined in a combined tool. Subsequently, the most suitable arrangement of the part on the sheet metal strip is selected and the sheet metal coil is selected as a semi-finished product for production. Furthermore, technological calculations are performed and drawing documentation of the tool is made. Based on the calculated values, the production machine Mecanica Exacta model CC250 from the company Formetal s.r.o.
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Production of a hollow pin by cold forming
Šanca, Kristián ; Řiháček, Jan (referee) ; Jopek, Miroslav (advisor)
The hollow pin with a length of 45 mm and a diameter of 28 mm made of 12 050 steel is produced by cold cold forming. It showed defect-translation and the goal was to eliminate it by optimization. 10 variants were proposed, of which No. 10 was without defects and the goal of the work was met. The forming process was simulated by Simufact Forming software. The semi-finished product is a block made of a round bar 18 x 35.68. The part is manufactured on a process tool for 4 operations by a combination of upsetting and extrusion. The machine used is the CBF-204L automatic machine. The required force is 3 042 kN. The price of 1 piece is CZK 19.59. 120,000 pieces are produced annually.
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Piston rod eye production
Hořava, David ; Jopek, Miroslav (referee) ; Lidmila, Zdeněk (advisor)
The bachelor's project elaborated design of technology production of the piston rod eye in series of 45 000 pieces. The piston rod eye is made of steel rod C45E by die forging. Pursuant to of the literary pursuit and necessary technological calculations was chosen a pneumatic – hydraulic hammer KHZ 4A, from the company called Šmeral, with a forming energy of 50 kJ, for forging of component. Cross wedge rolling machine was chosen for overdosage of forged piece in form of double piece. Shearing press LKOA 200, from the company called Šmeral, with a forming force of 2 000 kN, was chosen for shearing of forged piece. At the end, the technical – economic evaluation of material costs was calculated.
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Production Possibilities of Press Brakes
Hrazdíra, Michal ; Jopek, Miroslav (referee) ; Řiháček, Jan (advisor)
The bachelor thesis deals with the production possibilities of press brakes. This is a literary research, in which the aim of the work is to describe the principle of bending. It also focuses on common and special tools and their use in engineering practice. The first part of the work is focused on general bending technology, which discusses the basic principles and possibilities of this method. The main chapter is the bending itself, where the individual types of machines, their components, tools and clamping systems are introduced and described. Furthermore, modern tools and their application in engineering practice are presented. In the last part, the production of the switchboard cabinet is presented on a CNC press brake.
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Production of plough share screw
Hladík, Milan ; Jopek, Miroslav (referee) ; Forejt, Milan (advisor)
The bachelor's thesis presents a design of plow screw production technology used to attach the blade to the plow frame. The screw is made of structural steel 14,140, in a production series of 120,000 pcs / year. From the possible technologies, the technology of volume cold forming was chosen. From the literature sources of the issue of volume cold forming, the optimal procedure of screw production was proposed. With the help of design, technological and control calculations, a machine was designed and subsequently a production tool, for which drawing documentation was prepared. With the help of technical - economic evaluation, the costs of component production were compared using volume forming and machining.
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Manufacture of Chandelier Hinge
Mergeščíková, Lenka ; Jopek, Miroslav (referee) ; Žák, Ladislav (advisor)
The master’s thesis presents a design for the technology of manufacture of a chandelier hinge from the material ČSN 42 3005 (Cu99.5) with a sheet thickness of 0.5 mm. Due to the spherical shape of the part and the series 40 000 parts per year, the technology of deep drawing was chosen for two drawing operations, while the redrawing is performed by reverse deep drawing. Due to the nature of the component, the additional technology is shearing. The manufacturability of the part was verified using numerical simulation in the PAM-STAMP software. The forming process is performed using three forming tools on three different presses. For the first, combined tool, an LE 160C eccentric press is used. A hydraulic press ZHO100 is applied in the second tool for the reverse drawing, and finally, an eccentric press LEK160 is applied for the shearing in the third operation. With the selected profit value of 25 %, the final price for the component was set at CZK 104.17. The turning point occurs after reaching 16 248 parts.
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