The article describes application of selected methods of technical diagnostics for assessing the operating status of precision gearboxes. Within the confines of experimental measurements in the field of physical metallurgy materials of diagnosed system were being examined while taking into account the process of degradation of material properties during operation of monitored gearboxes. Measurements and collecting of dynamic data were realized on 4 selected gearboxes where a high-frequency vibrations and acoustic emission (noise) measurements were carried out. Retrieved values were subsequently used for mutual correlation and verification of applied methods. Results of both selected methods underlined unsatisfactory operation status with 3 inspected gearboxes. Measured values were identified as being above suggested caution limit of Alarm 2, representing a level of danger.

Additive manufacturing is becoming one of the most utilized tools in an increasing number of fields from Industry 4.0 concepts, engineering, and manufacturing to aerospace and medical applications. One important issue with additive-manufactured components is their orthotropic behaviour where mechanical properties are concerned. This behaviour is due to the layer-by-layer manufacturing process and is particularly hard to predict since it depends on a number of factors, including the manufacturing parameters used during the manufacturing process (speed, temperature, etc.). This study aimed to create and train an artificial neural network-based predictive model using empirical tensile strength data obtained from additive manufactured test parts using the FDM method and PLA material. The predictive model was designed to predict mechanical characteristics for different orientation axis, which were used to set the material properties for finite element analysis. Results indicate a strong correlation between predicted finite element analysis behaviour and real-world tests on additive-manufactured components. The neural network model was trained to an accuracy of ~93% for predicting the mechanical characteristics of 3D-printed PLA material. Using the predicted mechanical characteristics for defining a custom orthotropic material profile in finite element analysis, the simulated failure mode and the behaviour of a complex geometry component agreed with the real-world test.

This paper describes attributes of newly designed variant approach of computer support system of technological preparation of production. Knowledge system for automation of production of technological documentation was developed for technology of surface processing of metal. The paper describes the design of coding system for sorting mechanical parts into groups with similar mechanical parts, either by their shape, dimensions or used technology. Subsequently, it points out to attribute of the system – uploading and modification of sample technological documentation.

The rapid development of manufacturing in recent years has led to a significant expansion of the technological capabilities of modern metal-cutting equipment. Therefore, the modern approach to intensifying production requires an advanced fixture design. Design and manufacture of flexible fixtures capable of machining similar shapes and sizes of complex geometry parts reduce setup time. The article aims to design flexible fixtures for parts such as one-piece connecting rods under incomplete locating conditions. The advantages are the minimum number of parts and tool availability for multi-axis machining connecting rods in one setup. This approach, combined with up-to-date machining centers and industrial robots, can increase the production efficiency of manufacturing non-removable connecting rods. This effectiveness is in a decrease in the number of operations by 5–7 times, fixtures—by 3–4 times, and machine tools—by 3–5 times, depending on the type of a non-removable connecting rod and its design features. The numerical simulation results of the proposed fixture design confirmed the comprehensive technological capabilities and dynamic characteristics. Particularly, a decrease in displacements and oscillation amplitudes up to 7% compared to the full-basing locating chart was provided. It is determined that the system “fixture–workpiece” entirely meets all the strength, accuracy, and rigidity parameters, which allows you to perform machining with intensive cutting modes. The amplitudes of oscillations do not exceed the tolerances on the dimensions of these surfaces, established by requirements for non-removable connecting rods, and all displacements are elastic. During numerical simulation, the workpiece position remained stable at all machining steps.