The aim of this work is to evaluate the possibility of inexpensively producing small-batch polymer sheet components using robotized single point incremental forming (SPIF) without backing plate support. An innovative method of thermal and ultrasound assisted deformation of a polymer sheet is proposed using a tool with a sphere mounted in a ring-shaped magnetic holder, the friction of which with the tool holder is reduced by ultrasound, and the heating is performed by a laser. The heated tool moving on the sheet surface locally increases the plasticity of the polyvinyl chloride (PVC) polymer in the contact zone with less deforming force does not reducing the stiffness of the polymer around the tool contact area and eliminating the need for a backing plate. The free 3D rotating ball also changes the slip of the tool on the surface of the polymer sheet by the rolling, thereby improving the surface quality of the product. The finite element method (FEM) allowed the virtual evaluation of the deformation parameters of the SPIF. Significant process parameters were found, and the behavior of the heated polymer sheet was determined.

The integrity of delaminated composite structures can be restored by introducing a thermally-based healing effect on continuous fiber-reinforced thermoplastic composites (CFRTPC). The phenomenon of thermoplastics retaining their properties after melting and consolidation has been applied by heating the delaminated composite plates above their glass transition temperature under pressure. In the current investigation, the composite is comprised of Methyl methacrylate (MMA)-based infusible lamination resin combined with benzoyl peroxide initiator, which polymerizes into a Polymethyl methacrylate (PMMA) matrix. For the reinforcement, unidirectional 220 gr/m² glass filament fabric was used. Delamination damage is artificially induced during the fabrication of laminate plates. The distributed delamination region before and after thermally activated healing was determined by using non-destructive testing with active thermography. An experimental approach is employed to characterize the thermal healing effect on mechanical properties. Experimentally determined technological parameters for thermal healing have been successfully applied to repair delamination defects on composite plates. Based on the compression-after-impact (CAI) test methodology, the intact, damaged, and healed composite laminates were loaded cyclically to evaluate the healing effect on stiffness and strength. During the CAI test, the 3D digital image correlation (DIC) technique was used to measure the displacement and deformation fields. Experimental results reveal the difference between the behavior of healed and damaged specimens. Additionally, the numerical models of intact, damaged, and healed composite laminates were developed using the finite element code LS-Dyna. Numerical models with calibrated material properties and tie-break contact constants provide good correlation with experimental results and allow for the prediction of the mechanical behavior of intact, damaged, and healed laminated plates. The comparison analysis based on CAI test results and modal characteristics obtained by the 3D Laser Doppler Vibrometer (Polytec GmbH, Karlsbad, Germany) proved that thermal healing partially restores the mechanical properties of damaged laminate plates. In contrast, active thermography does not necessarily indicate a healing effect.

This paper presents research on the mechanical characteristics of a synchronous axial magnetic coupling. The influence of the coupling structure on torque and axial force was analyzed. The considered parameters of the structure include the half-clutch diversity, the air-gap length between adjacent magnets, the magnetic characteristics of the backings’ material, and the shape of the backings. It was discovered that the ferromagnetic backings that partially shroud magnets of the coupling cause a significant decrease of the maximum torque. The maximum torque and the maximum axial force decrease in nonlinear manner in response to the increasing magnets’ height diversity, and the sensitivity of the parameters is larger in the upper range of the diversity. It was also disclosed that the air-gap length between the adjacent magnets has a minor influence on torque if the total volume of magnets is constant. A quantitative comparison of the maximum torque and maximum axial force for the couplings with both ferromagnetic backings, one ferromagnetic backing and with non-ferromagnetic backings is provided. The results were obtained using a 3D FEM numerical simulation. Physical experiments were performed for the numerical model verification.

Bearing-grade PEEK composites are intended to improve sliding performance, but filler addition does not necessarily reduce friction. This study compared the dry sliding tribological behaviour of neat PEEK and hybrid PEEK containing PTFE, graphite, and carbon fibre against 42CrMo4+QT steel. Ring-on-block tests were performed at nominal PV values of 0.3–3.2 MPa·m/s, contact pressures of 0.87–5.82 MPa, and sliding velocities of 0.26–0.55 m/s. Each material–condition combination was tested using three independent specimens. Coefficient of friction was calculated from simultaneously measured tangential and normal forces, and subsurface temperature was recorded continuously. Initial and post-test surfaces were examined using optical and extended depth-of-field microscopy. Group mean COF values ranged from 0.052 to 0.123. Hybrid PEEK exhibited a higher numerical mean COF than neat PEEK in all six operating conditions, with relative differences of approximately 1.53–8.36%. Two-factor ANOVA estimated an overall hybrid-minus-neat difference of +0.003388 COF units (95% CI 0.001279–0.005496; p = 0.0029), whereas none of the six condition-specific neat–hybrid comparisons was significant after Holm correction. Initial temperature, maximum temperature, and baseline-normalised temperature rise were reported for every specimen and treated descriptively. Both materials reached stable sliding states without seizure or uncontrolled thermal escalation. Post-test EDF observations showed a denser pattern of fine grooves on neat PEEK, whereas hybrid PEEK exhibited comparatively smoother intervening regions interrupted by fewer but locally deeper features. Mass changes remained close to the capability of the applied balance and did not permit quantitative wear-rate comparison. The results show that the investigated hybrid formulation did not provide a dry-friction reduction advantage over neat PEEK under the tested conditions.