The contact pattern between gear teeth is one of the most significant indicators of proper gear operation. This paper presents an analysis of the contact pattern of gears with a sinusoidal profile. The gear geometry was obtained through direct solid simulation of the machining process. Generally, analytical, numerical, and experimental methods are used for contact pattern analysis in gearboxes. This article presents contact pattern investigations using numerical methods and a novel experimental method that utilizes pressure measurement films. A proprietary program using image analysis was used for the contact pattern analysis. The numerical studies utilized the Finite Element Method (FEM) and the CAD method. The results obtained from the presented methods show good convergence.

This paper presents the results of research on the impact of the use of different tools and the shape of the additional rivet, on the geometric quality of the joint, the energy consumption of the forming process, the distortion of the steel samples, and the load capacity of the joints. The tests were carried out for DX51D steel sheets with a thickness of 1.5 [mm] joined by using three different sets of tools. A steel rivet with a hardness of 400HV1 and various shapes was used for the tests. In addition to the full rivet, two types of rivet were used, the first with a through hole and the second with a depth of hole of 3 [mm]. The holes in the rivet had different diameters: 1.0, 1.5, 2.0 and 2.5 [mm]. The influence of changing the shape of the rivet (hole and its diameter) on the change in forming force and energy consumption of the joining process was analyzed. The lowest forming force was achieved for a rivet with a through hole and a hole diameter of 2.5 [mm]. The lowest joint forming force was obtained for the die with movable segments. For joints made with three tool arrangements and a series with a modified rivet, the amount of sheet metal deviation was analyzed. Of the three cases of arrangement of tools used to form the joint, the largest deviation of the sheets occurred at the clinch joint formed with a solid round die. In the case of a series of clinch-rivet joints with a modified rivet, the greatest deviation of the sheets occurred for the rivet with a hole of 1.5 [mm]. Changes in the geometric structure of the joint were also studied, and changes in the surface of the sheets in the joint area were observed. The highest value of the interlock in the joint was obtained when a solid rivet was used in the clinch-riveting technology. The strength of the joints was also identified in the lap shear test and the energy consumption at failure was determined. The use of a rivet increased the maximum load capacity to almost twice that of the clinch joint.

This paper presents the possibility of forming a pressed joint between two 1.5 mm thick sheets made of HX340 steel. The joint was formed using an additional deformable steel rivet with a hardness of 400HV1. Different distances of rivet pressing below the initial surface of the upper sheet were chosen: 0, 0.15, 0.30, 0.45 and 0.60 (in mm). For the mentioned rivet-pressing distances, forming tests were performed using an “SKB” die with three die depths: 1.45, 1.60 and 1.75 (in mm). Observations and measurements of the characteristic geometric dimensions of the interlock were made. Furthermore, the strength of the clinch-riveted joints was analysed. Changing the depth of the die by 20%, i.e., from hd = 1.45 mm to hd = 1.75 mm for the same rivet press-in depth (of = 0%), resulted in a 12% reduction in the forming-force value. The maximum load capacity of the joint in the shear test decreased by 3.5% for the mentioned joint variant. The greater the rivet press-in depth used in the joint (of), the greater the value of the interlock size (tu). Increasing the value of rivet-pressing depth below the initial surface of the upper sheet from 0 mm to 0.6 mm resulted in an increase in the size of the interlock (tu) by 136% (for hd = 1.45 mm), by 128% (for hd = 1.60 mm) and by 85% (for hd = 1.75 mm).

The forming mechanism of clinch joints, for various materials arrangement, using a punch and a rigid die, is well known. The basic technological parameter of the process is the parameter X – the minimal thickness of the embossment. Usually, the lower the X parameter, the greater the joint interlock. This paper presents the possibility of forming a pressed joint for two 1.5 [mm] thick sheets made of HX340 steel. The joint was formed using an additional deformable steel rivet with a hardness of 400HV1. Different values of rivet pressing below the initial surface of the upper sheet were chosen: 0, 0.15, 0.30, 0.45 and 0.60 (in [mm]). The punch positioning accuracy was 0.01 [mm]. For the mentioned rivet pressing distances, forming tests were performed using an ‘‘SKB’’ die with three die depths: 1.45, 1.60 and 1.75 (in [mm]). Observations and measurements of the characteristic geometric dimensions of the interlock were made. Furthermore, the strength of the clinch-riveted joints was analysed. The greater the rivet pressing distance, the larger the interlock parameters. Furthermore, depending on the size of the rivet pressing distance, different failure mechanisms of the lap joint were observed in the tensile shear tests.

This paper presents the deformation of a joined sheet after the clinch riveting process. The DX51D steel sheet with zinc coating was used. The samples to be joined with clinch riveting technology had a thickness of 1 ± 0.05 mm and 1.5 ± 0.1 mm. The sheet deformation was measured before and after the joining process. The rivet was pressed in the sheets with the same dimension between the rivet axis and three sheet edges: 20, 30, and 40 mm. For fixed segments of the die, from the rivet side close to the rivet, the sheet deformation was greater than that of the area with movable segments. The movement of the die’s sliding element caused more sheet material to flow in the space between the fixed part of the die and movable segments. Hence, the sheet deformation in these places was smaller than for the die’s fixed element—the sheet material was less compressed. For sheet thickness values of 1.5 mm and a width value of 20 mm, the bulk of the sheet was observed. For a sheet width of 20 mm, it was observed that the deformation of the upper and lower sheets in the area of the rivet was greater than for sheet width values of 30 or 40 mm.

This publication presents the possibility of forming a clinched joint with the use of a deformable element such as a full rivet. An analysis of the joint load capacity was also performed for three values of the hardness of the rivet. The joints were formed in the same sheet with thickness t=1.5 [mm] made of DX51D+Z275 steel (which is commonly used for thin-walled structures). Additional rivets with hardness values 350HV1, 400HV1, and 420HV1 were used. The joints were made with a uniform punch and a die with movable elements. Load capacity tests were carried out in order to demonstrate the influence of the angle between the load force and the axis of the clinch riveted joint. H-shaped samples were made for load tests with the use of a modified Arcan test device. All joints were tested under the same static test conditions (the traverse speed of the testing machine was 10 mm/min). In addition, the characteristic geometric parameters of the interlock were measured on the joint cross-sections. In the case of connecting the sheets with a rivet of three different hardnesses: 350HV1, 400HV1, and 420HV1, the largest surface deviations of the sheets were observed for the connection with the 350HV1 rivet hardness. Increasing the hardness of the rivet from 350HV1 to 400HV1 and 420HV1 resulted in a reduction in sheet deviations. The deviations for the largest distance from the rivet axis in the case of the 400HV1 and 420HV1 rivet hardness were at a similar level. The highest value of the interlock parameter, which determines the joint load capacity, was obtained for the rivet with the highest hardness value (420HV1). The highest joint load capacity was obtained when using a rivet with a hardness of 420HV1 and the lowest for the rivet hardness of 350HV1.

In the publication, the results of an experimental analysis of joint formation by pressing of DX51D steel sheets with thickness of 1.5 (mm) with the use of a rigid punch and an additional deformable rivet of various shapes were presented. The influence of the use of a steel rivet with a diameter d = 5 (mm), similar to the dimensions of the forming punch in the case of the classic clinching variety on the interlock parameters was investigated. The used die was with a four movable segments—dedicated to connections made in the clinch-riveting technology by TOX ® PRESSOTECHNIK. In additional, experimental tests were made for joining sheets with a rivet of various shapes, i.e. with a through hole. Joints were formed and the correctness of the upper blockage in the lower sheet was observed on the joints cross-sections. The interlock parameters were measured for each joints samples. In order to compare the influence of using an additional rivet on interlock parameters and joints strength the traditional clinching joints were also made. The minimal thickness of the traditional clinching joint embossment for 2 sheets of 1.5 (mm) thickness for each was X = 0.75 (mm).

Clinching joints with an additional deformable rivet are modifications of the clinching joints. The clinch riveting (CR) joint is formed indirectly by a deformable rivet. The research included an analysis of CR joints' forming process for aluminum alloy sheets made of AW 6082 in T6 state condition and AW 5754 in three different state conditions: H11, H22 and H24. As a result of forming the joint for various sheet arrangements, the highest value of blocking the upper sheet in the lower sheet (tu) was obtained for the arrangements with two 5754-H24 aluminum alloy sheets. For such a large interlock parameter tu, the greatest thinning of lower sheet (tn) was obtained, which influenced the maximum tensile shear force and the joint failure mechanism. Based on the load-displacement diagrams obtained from the static shear test of lap joints, the total energy of failure and energy to achieve the maximum load capacity were calculated. The highest energy absorption to achieve the maximum load capacity, in the case of the same sheet materials, was obtained for the 5754-H11 aluminum alloy sheets. On the other hand, among the tested combinations, the highest value of energy absorption (for the joint maximum load capacity) was obtained for the sheet arrangement: top sheet AW 6082-T6 and the bottom AW 5754-H24. The highest value of the total energy up to fracture was obtained when the material of the top sheet was AW 6082-T6, and the bottom AW 5754-H22. For each sheet arrangement, a similar analysis of the joint strength parameters, interlock parameters and forming force were made.

The possibilities of the vision system for the assessment of the shape of semi-finished products for the production of copper seals for fuel installations in the automatic production process were analyzed.The used vision system was presented and an algorithm was developed to assess the roundness of manufactured semi-finished products.The paper presents the results of an experiment conducted on a designed and constructed test stand.The experiment aimed at demonstrating the suitability of the method for analysis of roundness deviation of parts.

Among the essential issues facing designers of strain wave gears, the provision for correct lubrication should be of paramount importance. The present paper presents the results of research on elasto-hydrodynamic oil film in meshing of a harmonic drive with an involute tooth profile. The research was carried out based on theoretical models developed by Dowson and Higginson. For the discussed structural problem, results of the study are presented graphically in the form of static characteristics of the oil film. Correct operation regimes were determined for two different oils. The paper also provides a review of information concerning the design and principle of operation of strain wave transmission.

Two types of hydrodynamically lubricated plain journal bearings were subject to examination differing in the method used to feed them with oil. The first type was fed from a lubrication pocket and the second from the bearing face side. Mathematical models were developed with two-way oil flow allowing to determine the oil film bearing capacity, the maximum pressure, the maximum temperature, and the film oil minimum height for given position of journal relative to solid bush. Static characteristics were developed used in the further course of the study to compare operating parameters of the considered types of bearings. Another issue considered in the paper is the effect of oil VG grade on bearing performance with conditions of oil feeding taken into account and results of the research presented.

The paper presents the results of the experimental studies of the clinching joints upper sheets shape deformation. In the joint forming process a one punch and different die were used. The numbers of movable segments were: two, three and four.

This paper presents a research of the lap joint shear strength of S350GD+Z sheet material joined by resistance spot welding. The resistance spot welding process was done for five values of welding current. The joints strength structure analysis was done for the shearing curves. The influence of the welding current on the joints maximum strength and the shear curve of the resistance spot welded joints was presented. Welding current increase influence efficiency on the joints strength was analyzed. The analysis of the cold plastic formed joining technologies (clinching) was also presented. The clinching joints were made by using different tool types and uniform values of embossment minimum thickness. The influence of tool shape on the joint strength was described. In the case of round clinching joints the influence of forming force increase on the joints strength was studied.

The paper presents the results of the experimental studies of the clinching joints upper sheets shape deformation. In the joint forming process a one punch and different die were used. The numbers of movable segments were: two, three and four.

Presented was the results of experimental analysis of single riveted joints strength. The joints shear strength was determined in temperature of 23, 400, 600, 800 Celsius degrees. The obtained results helped to explain how the temperature affects on the joint load characteristic. The experimental research was carried out for zinc coated S350GD sheet metal material.

The paper deals with the numerical stress calculation in the flexspline tooth rim of the harmonic drive. Due to the complex geometry of the toothed ring in the flexspline, the teeth were modeled as a ring, which height corresponded to the particular stress concentration in the teeth. To study the effect of type of wave generator on the stress distribution in the flexspline, the following models were elaborated: two-roller, four-roller, cam, and disk. The stress calculations were performed for the two cases: a zero torque load and the torque load value, corresponding to the true operation conditions of the hermetic harmonic drive.

The application of X-ray micro-diffraction to study the local changes in austenite content in clinching joints made of DP 600 steel is presented. The relations between various parameters of the cold pressing process and the microstructure and the austenite content in the individual parts of the clinching joints are shown.

The clinching joining technology is one of the most popular joining technologies by redrawing sheet material. The joining process parameters, the sheet material and its arrangements influences joints' strength. Cylindrical axial-symmetrical joints formed by using rigid die and punch are still developed. The change of the rigid die on the die with movable segments affect the forming process and joint strength parameters. So there is a need to do experimental researches of the possibilities of joint formation by unchanged punch geometry and different die shape. In this article the forming process parameters (forming force, process energy consumption and its standard deviations) and joints strength parameters (maximum shearing force, total dissipated energy and dissipated energy up to 0.3 maximum force), according to the ISO 12996 standard, for the joints formed with using die with 2, 3 and 4 movable segments were presented. The punch geometry was unchanged and the minimum thickness of the embossment was also unchanged. For the die with 2 and 4 segments the load force direction influence on the joints strength was also presented.

The article presents the analysis of the structure of the load capacity of riveted joints. For the four joining systems the lap joint specimens were made and tested in the shearing test. The joints were prepared for the three combinations of the DC01 steel and EN AW-5754 aluminium alloy sheets with the thickness of 2mm. On the basis of the obtained load-elongation diagram tensile shear test curves, the basic parameters defined in the ISO/DIS 12996 standard were determined. In the case of the conventional riveted joints the maximum load capacity of the joint is determined by the strength of the fastener. For the joints with aluminium-steel blind rivet, the load capacity of the joint was on the strength limit of the rivet tubular part and on the strength limit of the sheet material. The strength of the SSPR joint is determined by the mechanical properties of the material of the joined sheets. From all sheets and rivet specimens arrangements the highest load capacity of the joint was obtained for the DC01 sheet material joints, and the lowest load capacity of the joint was obtained for the EN AW-5754 sheet material joints.