Papers by Wojciech Kacalak
Materials, 2021
This paper presents the fundamentals of the design and applications of new worm gear drive soluti... more This paper presents the fundamentals of the design and applications of new worm gear drive solutions, which enable the minimisation of backlash and are characterised by higher kinematic accuracy. Different types of worm surfaces are briefly outlined. Technological problems concerning the principles of achieving a high degree of precision in machining are also described. Special attention is paid to the shaping of conical helical surfaces. Increasing the manufacturing precision of drive components allows one to achieve both lower backlash values and lower levels of its dispersion. However, this does not ensure that backlash can be eliminated, with its value being kept low during longer periods of operation. This is important in positioning systems and during recurrent operations. Various design solutions for drives in which it is possible to reduce backlash are presented. Results of experiments of a worm gear drive with a worm axially adaptive only locally, in its central section, ar...
Operacje obrĂ³bki Å›ciernej jako operacje koÅ„cowe w caÅ‚ym procesie obrĂ³bki majÄ… decydujÄ…cy wpÅ‚yw na... more Operacje obrĂ³bki Å›ciernej jako operacje koÅ„cowe w caÅ‚ym procesie obrĂ³bki majÄ… decydujÄ…cy wpÅ‚yw na dokÅ‚adność ksztaÅ‚towÄ… i wymiarowÄ… obrabianych elementĂ³w. IstotnÄ… grupÄ… przyczyn niedokÅ‚adnoÅ›ci wpÅ‚ywajÄ…cych na dokÅ‚adność obrabianych elementĂ³w sÄ… odksztaÅ‚cenia ukÅ‚adu obrĂ³bkowego wynikajÄ…ce z oddziaÅ‚ywania siÅ‚ szlifowania. W pracy dokonano analizy wpÅ‚ywu odksztaÅ‚ceÅ„ ukÅ‚adu technologicznego w procesie automatycznego szlifowania maÅ‚ych elementĂ³w ceramicznych. OkreÅ›lono zależnoÅ›ci umożliwiajÄ…ce okreÅ›lenie wielkoÅ›ci odchyÅ‚ek poÅ‚ożenia wzglÄ™dnego przedmiotu obrabianego oraz narzÄ™dzia Å›ciernego dla ukÅ‚adu N wrzeciennikĂ³w. Przeprowadzona analiza umożliwia okreÅ›lenie wielkoÅ›ci odksztaÅ‚ceÅ„ ukÅ‚adu obrĂ³bkowego w zależnoÅ›ci od rozkÅ‚adu naddatku na poszczegĂ³lne wrzecienniki oraz umożliwia okreÅ›lenie miejsc zamocowaÅ„ wrzeciennikĂ³w realizujÄ…cych zabiegi obrĂ³bki koÅ„cowej, decydujÄ…cej o dokÅ‚adnoÅ›ci wymiarowej obrabianych elementĂ³w.
Journal of Machine Engineering, 2016
Authors propose a method of normalizing and analyzing structures, enabling automated cross-compar... more Authors propose a method of normalizing and analyzing structures, enabling automated cross-comparison of features observed in tested structures against predefined ones (both correct and incorrect reference elements). Application of this method, enables usage of numerical methods and neural networks for rapid classification of elements, while maintaining high level of flexibility, uncertainty and variety of input data. Additionally, a language, enabling symbolic representation of mechanical elements is presented and used in the demonstration of the proposed method applied to mechanical shafts. Authors explore one simple, and two more complex calculation models aimed at automation of the evaluation and rating of mechanical elements, with a purpose of improving the design and quality monitoring processes. Increase in efficiency of these processes results from applying proposed method as a tool for reducing common mistakes, faults, quality assessment time of large amounts of similar ele...
Mechanik, 2018
This paper many different methods of generating the topography of the grinding wheel surface and ... more This paper many different methods of generating the topography of the grinding wheel surface and the methodology for assessing the compatibility of models with the surface of real tools was presented. The methodology was indicated that certain features regarding the shape and position of the highest vertices are decisive for assessing the model’s conformity with the real surface of the grinding wheel. The significance of not only the form of the distribution of the vertices of the grains was emphasized, but also the significance of the fragment of the probability density function relating to the highest vertices and the autocorrelation of the vertex position as the most important feature, which often are overlooked in the models described in the literature.
Mechanik, 2018
Estimation of the machining capacity of grinding wheels after the conditioning process, during th... more Estimation of the machining capacity of grinding wheels after the conditioning process, during their operation and after the grinding process is an important and complex problem. The article presents a methodology for the evaluation of wheel topography using a new height indicator and sharpness of abrasive grains, which enables determination of the machining potential of the wheel to be tested. Analysis of the developed parameter was carried for three different grinding wheels and for two different state after the conditioning process and after 30 minutes of grinding.
Mechanik, 2018
In order to determine the micro-finishing abilities of diamond abrasive films, surface topography... more In order to determine the micro-finishing abilities of diamond abrasive films, surface topography was analyzed using confocal microscopy OLS 4000 Olympus. In the analysis of stereometric features of the abrasive surface, it was considered that during the micro-finishing process the abrasive surface is pressed against the workpiece. The procedure for determining the changes in topography of the film surface in the treatment area was developed as a result of elastic deformations of the film carrier, the grain binding binder and the pressure roller. New parameters for the activity of abrasive grains were developed and the values of grain hollows, depending on the pressure value in the machining zone and the nominal size of the grain (3, 9, 15, 30 μm) were determined.
Mechanik, 2017
In the publication a topographic characteristics of the contact zones in the contact joints for t... more In the publication a topographic characteristics of the contact zones in the contact joints for the surfaces formed in the grinding process was presented.
Mechanik, 2018
Micro-finishing with abrasive foils consists in performing several smoothing operations using abr... more Micro-finishing with abrasive foils consists in performing several smoothing operations using abrasive foils of smaller and smaller nominal grain size in order to obtain a high smoothness of the surface being processed. The abrasive grains on the surface of the IDLF film, in particular with the grain size of 3 and 9 μm, are often arranged in the form of aggregates. This phenomenon has been described with the use of new parameters to assess the degree of surface development of aggregates. Due to the one-time use of diamond abrasive foils in the smoothing process and the associated tool costs, the principle of selecting abrasive foils for subsequent treatments was developed in such a way that the potential for reducing the unevenness height was used optimally.
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Papers by Wojciech Kacalak