Machine Design

UNIVERSITY OF NOVI SAD
FACULTY OF TECHNICAL SCIENCES

ADEKO ASSOCIATION FOR DESIGN, ELEMENTS AND CONSTRUCTIONS
machine design
Vol.7(2015) No.3
ISSN 1821-1259
editor IN CHIEF:
prof. phd. sinia kuzmanovi
novi sad, 2015

Publication
Machine Design
editor IN CHIEF
Prof. Sinia KUZMANOVI, Ph.D. Eng., University of Novi Sad, Faculty of Technical Sciences
CO-editor
Assist. Prof. Milan RACKOV, Ph.D. Eng., University of Novi Sad, Faculty of Technical Sciences
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MACHINE Design / editor in chief Sinia Kuzmanovi. - 2009- .- Novi Sad :

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ISSN 1821-1259 (tampano izdanje)
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University Politehnica Timisoara, University of Ni, University of Belgrade,
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Romania Ni, Serbia Belgrade, Serbia
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Bulgarian Academy of Sciences, University of Chemical Technology and Ss. Cyril and Methodius University,
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Sibiu, Romania Ni, Serbia Madrid, Spain
Prof. Ilare BORDEAU, Ph.D. Prof. Svetislav JOVII, Ph.D. Prof. Victor E. STARZHINSKY, Ph.D.
Politehnica University of Timisoara, University of Kragujevac, V.A. Belyi Metal-Polymer Research Institute of
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Universitary Centre of Baia Mare, University Politehnica Timisoara, University of Kragujevac,
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Slovak University of Technology, University of Arts in Belgrade, Lublin University of Technology,
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University of Montenegro, Chief Expert on Gears, Design and Technology, Slovak University of Technology,
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Technical University of Sofia, Poznan University of Technology, University of Belgrade,
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University College of Nyregyhza University of East Sarajevo, Angel Kunchev University of Rousse, Faculty of
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Izhevsk State Technical University, University of ilina Slovak University of Technology in Bratislava,
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Izhevsk, Russia ilina, Slovakia STU, Trnava, Slovakia
Prof. Ladislav GULAN, Ph.D. Prof. Athanassios MIHAILIDIS, Ph.D. Prof. Miroslav VERE, Ph.D.
Slovak University of Technology, Aristotle University of Thessaloniki, Faculty of Slovak University of Technology,
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Bratislava, Slovakia Machine Design, Thessaloniki, Greece Bratislava, Slovakia
Prof. Csaba GYENGE, Ph.D. Prof. Vojislav MILTENOVI, Ph.D. Prof. Simon VILMOS, Ph.D.
Technical University of Cluj-Napoca, University of Ni, Budapest University of Technology and
Faculty of Machine Building, Faculty of Mechanical Engineering, Economics, Department of Machine and Product
Cluj-Napoca, Romania Ni, Serbia Design, Budapest, Hungary
Prof. Sava IANICI, Ph.D. Prof. Radivoje MITROVI, Ph.D. Prof. Jovan VLADI, Ph.D.
Eftemie Murgu University of Resita, University of Belgrade, University of Novi Sad,
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Resita, Romania Belgrade, Serbia Novi Sad, Serbia
Prof. Milan IKONI, Ph.D. Prof. Slobodan NAVALUI, Ph.D. Prof. Rushan ZIATDINOV, Ph.D.
University of Rijeka, University of Novi Sad, Fatih University,
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Rijeka, Croatia Novi Sad, Serbia Istanbul, Turkey
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University of Belgrade, "Angel Kanchev" University of Rousse, University of Novi Sad,
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Belgrade, Serbia Rousse, Bulgaria Novi Sad, Serbia
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Prof. Ranko ANTUNOVI, Ph.D. Prof. Milan IKONI, Ph.D. Prof. Milosav OGNJANOVI, Ph.D.
University of East Sarajevo, University of Rijeka, University of Belgrade,
Faculty of Mechanical Engineering, Faculty of Engineering, Faculty of Mechanical Engineering,
East Sarajevo, Bosnia and Herzegovina Rijeka, Croatia Belgrade, Serbia
Prof. Mirko BLAGOJEVI, Ph.D. Prof. Dragoslav JANOEVI, Ph.D. Prof. Rastislav OSTAKOV, Ph.D.
University of Kragujevac, University of Ni, University of Novi Sad,
Faculty of Engineering, Faculty of Mechanical Engineering, Faculty of Technical Sciences,
Kragujevac, Serbia Ni, Serbia Novi Sad, Serbia
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University of Novi Sad, University of Chemical Technology and University of Banja Luka,
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University of Novi Sad, University Politehnica Timisoara, Slovak University of Technology in Bratislava,
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University of Novi Sad, Poznan University of Technology, Slovak University of Technology,
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University of Novi Sad, University of Novi Sad, Budapest University of Technology and
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Novi Sad, Serbia Novi Sad, Serbia Design, Budapest, Hungary
Prof. Miroslav GOJO, Ph.D. Prof. Vojislav MILTENOVI, Ph.D. Prof. Jovan VLADI, Ph.D.
University of Zagreb, University of Ni, University of Novi Sad,
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Zagreb, Croatia Ni, Serbia Novi Sad, Serbia
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University of Ljubljana, University of Novi Sad, University of Mostar,
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Ljubljana, Slovenia Novi Sad, Serbia Mostar, Bosnia and Herzegovina
Prof. Sava IANICI, Ph.D. Prof. Dragoljub NOVAKOVI, Ph.D. Prof. Milan ZELJKOVI, Ph.D.
Eftemie Murgu University of Resita, University of Novi Sad, University of Novi Sad,
Faculty of Engineering, Faculty of Technical Sciences, Faculty of Technical Sciences,
Resita, Romania Novi Sad, Serbia Novi Sad, Serbia
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Machine Design publishes fundamental research about mechanical
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Editor in Chief,
Prof. Ph.D. Sinia Kuzmanovi

CONTENTS:
Preliminary note
1. Impact Analysis Heating Plants to the Environment as an Initial Step in Determining the
Optimal Cogeneration Plants
Milan RADOSAVLJEVI, Milun BABI .............................................................................................................. 69
Research papers
2. Obtaining the Maximum Load of the Bending Load Element Considering the Variation of the
Geometric Characteristic and Property of the Materials
Ilios VILOS, Ljupco TRAJCEVSKI ........................................................................................................................ 75
3. Construction Solution and Estimate of Important Elements Assemblies of Log Splitter

Milan TICA, Branislav OLI, Slobodan APLJAK ............................................................................................. 79
4. End-Milling Force Control System With Surface Roughness Monitoring

Uros ZUPERL, Franc CUS ...................................................................................................................................... 85
5. Application Development for Learning About Graphic Systems Integrated

in the Platform of E-Learning
Dragoljub NOVAKOVI, Stefan UREVI, Ivan PINJER, eljko ZELJKOVI,
Nemanja KAIKOVI ............................................................................................................................................. 89
6. Vibration Monitoring System Based on PIC Microcontroller

Ljubomir VRAAR, Milo MILOVANEVI, Petra KARANIKI ..................................................................... 93
7. Applicable Importance of Vibro-Diagnostics in Predictable Maintenance of Naisus

Aqueduct System
Milo MILOVANEVI, Ljubomir VRAAR, Sanjin TROHA ............................................................................ 97
MANUSCRIPT FORMAT
machine design, Vol.7(2015) No.3, ISSN 1821-1259 pp. 69-74
Preliminary note
IMPACT ANALYSIS HEATING PLANTS TO THE ENVIRONMENT AS AN INITIAL STEP IN

DETERMINING THE OPTIMAL COGENERATION PLANTS
Milan RADOSAVLJEVI 1, * Milun BABI 2
1 Zastava Tapacirnica a.d., Kragujevac, Republic of Serbia
2 University of Kragujevac, Faculty of Engineering Science, Republic of Serbia
Received (20.05.2015); Revised (08.06.2015); Accepted (11.06.2015)
Abstract: To facilitate the RS authorities, local governments, the management of heating-power plant in the RS and
entrepreneurs to make the best possible decisions regarding the successful redesign of the existing heating-power plant
for their conversion to highly efficient cogeneration facilities and/or to build small and micro-cogeneration units, RS,
was made in the context of this work a detailed analysis of the influence of heating-power plant on the environment. To
this end several months of investigations have been carried out in member states Business Association of heating plants
RS that have allowed to reach a sustainable scenario of mass introduction of cogeneration in the RS. The results of this
analysis are an integral part of the internet database that will after completion of the project constitute an important
basis for the popularization of application cogeneration production of heat and electricity.
Key words: emissions, cogeneration, energy consumption
1. INTRODUCTION cogeneration plants (III 42013) "This project is under the

direction of prof. Dr. Milun Babic, implemented at the
Unwanted greenhouse effect is now a key issue of Faculty of Engineering Science, University of
environmental protection at national and international Kragujevac, and funded by the Ministry of Education,
level. One of the main ways of reducing emissions of Science and Technological Development, with the
gases that cause the greenhouse effect is energy support of the most important industrial companies and
efficiency and rational energy management at the level of the Business Association of heating plants RS. This
each sector. "consortium team" has estimated that, under the current
In December 1997, 38 industrialized countries have circumstances, the city's heating-power plant, with
committed to reduce emissions by 5% in the period from domestic thermal power plants are the biggest emitters of
2008th to 2012th compared to the level of 1990th GHGs, and that this shows, in addition to other economic
emissions. The protocol was signed in Kyoto, as a very and energy benefits for the RS, establishing Cogeneration
important objective is the reduction of gases that cause production in member states can essentially puts reduced.
the greenhouse effect, while at the same time and to Therefore, in the present research projects, among other
prevent global climate change [1]. things, done the research:
Conservative influence companies still too strong and
the possible potential for cogeneration in RS
does not allow that to vigorously reduce environmental
the potential for cogeneration in district heating
pollution. Evidence of the failure of the Conference on
systems RS
Climate Change in Copenhagen (Climate Conference in
analysis of consumption of coal/fuel oil in power
Copenhagen from 6 to 18 December 2009th), where he
stations RS and the corresponding emissions and
brought together the world's political and professional
projections of energy consumption,
elite, but significant agreement on the reduction of
as important a design-development and economic basis
environmental pollution absent.
for:
With the ambition to integrate into the EU, our country
the successful redesign of the existing heating-power
has for several years stimulate scientific and industrial
plant for their conversion to highly efficient
projects with the intention to apply the regulations of the
cogeneration facilities and
Kyoto Protocol and other legislation in force in the EU.
design and development of small and micro-
One such project, which the Republic of Serbia (RS) is
cogeneration plants in the RS.
trying to create the appropriate conditions for a quality
approach to reducing greenhouse gas emissions (GHG)
emissions on its own territory the project "Research 2. COGENERATION
cogeneration potential in the municipal and industrial
power plant the Republic of Serbia and opportunities for Cogeneration is the most suitable for achieving the aims
the revitalization of the existing and building new of energy efficiency and reducing emissions. The share of
*Correspondence Authors Address: Zastava Tapacinica a.d., 34000 Kragujevac, Serbia
Milan Radosavljevi, Milun Babi: Impact Analysis Heating Plants to the Environment as an Initial Step in Determinig
the Optimal Cogeneration Plants ; Machine Design, Vol.7(2015) No.3, ISSN 1821-1259; pp. 69-74
cogeneration in global electricity production is still 2.2. The potential of CHP in district heating systems
relatively small at around 9% [2].
CHP systems can play an important role in achieving The total installed capacity of sources of centralized heat
significant primary energy savings and in this way supply in cities of the Republic of Serbia is about 6597
reducing GHG emissions. However, it is not always MWt [9]. The connected consumer power is about 6000
certain that the cogeneration will reduce overall MWt, of which about 82% within the housing and about
emissions. It depends on the system for cogenerationand 18% within office buildings. The number of dwellings
also from technologies used for separate production of with central heating installations (720495), connected to
electricity and heat in a region or country, but also the centralized systems is about 481660, while about 240000
types of fuels used in these processes. Also, it is possible (8%) of flats supplied with thermal energy from local
that there is a reduction of one type of polluting boiler [9].
substances (e.g.,CO2), and increase in the other Today in Serbia already have district heating systems,
(e.g.,NOx). which are composed of plants with cogeneration of heat
From all available cogeneration systems, internal and electricity (Belgrade, Novi Sad, Zrenjanin, Sremska
combustion engines have the greatest potential for a Mitrovica, Kragujevac, Bor) powered with gas and liquid
negative impact on air quality, primarily due to high fuels, ie coal. In addition to existing plants in Serbia, the
emissions of NOx and non-combustible hydrocarbons. possible construction of new ones, taking into account the
CHP increased in most EU countries, increasing the share already available consumption of residential, public and
of CHP has been slower than expected. Apart from the commercial buildings.
prescribed directives for energy efficiency and the Table 1. presents the system of more than 100 MWt of
rational use of energy and the EU has included a specific installed heat power, representing about 85% of the total
Directive [4,5,6,7], governing the use of CHP and installed capacity of consumers in Serbia and provide a
acquiring the status of privileged energy producers. real opportunity for the effective implementation of
Participation in the existing cogeneration CHP or in the cogeneration [9].
total production of electricity in Serbia (0.8% in 2004) is
much less than the EU average (12.4%) [8]. Table 1. Centralized systems installed power consumers
2.1. Possible potential for cogeneration in Serbia over 100 MWt
The installed capacity of electric power source for EPS Size of consumption of thermal energy
(Elektroprivreda Serbia) is 8355 MW, of which 5171 MW City [MWt]
lignite-fired thermal power plants, 353 MW in CHP fuel Housing Business
oil or natural gas, and the rest of the flow (1849 MWe) Beograd 1832 650 2482
and accumulation (982 MW) hydroelectric power plants Bor 165 47 212
[9]. The total installed power, cogeneration accounts for
Kragujevac 112 255 367
4.2% [9], but the actual participation of cogeneration in
Kruevac 54 47 101
the total installed capacity of even greater when taking
Ni 168 67 235
into account the capacity of existing condensing block of
Novi Sad 448 203 651
thermal power plants "Nikola Tesla" (blocks A1 and A2)
Obrenovac 74 26 100
and "Kostolac '' (blocks A1 and A2), which were
Panevo 136 30 166
reconstructed so as to permit the seizure of the money for
Poarevac 65 36 101
the purposes district heating systems in Obrenovac or in
Poarevac and Kostolac. Heating Novi Sad. Subotica 72 45 117
The decentralized plants for combined heat and power Trstenik 70 39 109
generation can achieve total efficiency level of up to 90%. Zrenjanin 62 48 110
This is a significant increase in overall efficiency in 3358 1439 4851
relation to the level of efficiency of 36% resulting in a
classic centralized condensation plants for power 3. ANALYSIS OF THE CONSUMPTION OF
generation [3]. COAL/CRUDE OIL IN POWER STATIONS
The EU has begun the changing process of regulation in OF THE REPUBLIC OF SERBIA
1997 with the aim of doubling the share of CHP in
EMISSIONS
electricity production from 9 to 18% by 2010.
Although the amount of electricity generated from
Zrenjanin and Sremska Mitrovica is done from This paper presents an analysis of the consumption of
cogeneration plants. primary energy heating plants of the Republic of Serbia,
70
as well as the value of the emissions of the same. Heating heating season (November 16th - 16 April), while others
plants which have been taken into consideration and using keep records of the beginning of January (beginning of
natural gas and other forms of energy, but these fuels are the year) and December (end of year). Data on fuel
represented to a lesser extent. Representative consumption by heating plants are summarized in Table
cogeneration plants are located in the following cities: 2. and Table 3. and shown graphically in Figure 1. and 2.
Kosjeri, Negotin, Trstenik, Majdanpek, Zajear, Bor,
Kruevac, Kragujevac, Novi Pazar, Knjaevac, Gornji
Milanovac, Kladovo, Batoina, Zemun, Valjevo and
Leskovac.
Table 2. Consumption of fuel for heat production
Year Coal [t] Crude oil [t]

2007/2008 72.420,56 13.153,882
2008/2009 77.444,46 12.776,551
2009/2010 75.460,84 12.394,386
Table 3. Fuel consumption for heat production

Fig.1. Graphic fuel consumption by type and quantity for
Year Coal [t] Crude oil [t] that year
2008 97.917,47 12.443,451
2009 118.675,20 15.609,595
2010 105.410,20 15.030,930
Data listed plants ie. data boilers (number of boilers,

manufacturer, year of production, type of boiler, power
boiler [MW], the fuel used), consumption [kW or MW],
type of consumer (area residential and business premises
[m2], sanitary hot water, hot water for process use steam
for process use), the number of working hours for
individual loads during the heating season and heating
season, the daily operation, or whether there are capacities
for production of electricity resulting from the collection
to be completed "Research cogeneration potential in the Fig.2. Graphic fuel consumption by type and quantity for
utility and industrial power plants of the Republic of that year
Serbia and the possibilities for revitalization of existing
and construction of new cogeneration plants "issued by 3.1. Emissions
the Ministry of Science and Technological Development.
This paper does not include all the information contained For most harmful gases released during the combustion of
herein for several reasons. One of them is confidential fossil fuels, the carbon dioxide (CO2), methane (CH4),
mentioned district heating and fear for publishing them, nitrous oxides (NOx), carbon monoxide (CO), non-
while other reason does not possess all the documents. methane volatile organic compounds and sulfur oxides
Viewing consumption and gas emissions from power (SOx).
stations above the Republic of Serbia, as the Calculation of the overall GHG emissions due to
representative of the heating season, which will display combustion of fossil fuels for heat generation in this paper
the 2007/2008, 2008/2009 and 2009/2010. years and was carried out according to the revised IPCC
heating seasons 2008, 2009 and 2010. The reason why the methodology [10].
heating season in the two ways is shown is that the The value of the calculated amount of gas emissions in
heating plant itself so keep records ie. a calculated the production of thermal energy for selected periods are
consumption of start heating season until the end of the presented in the following tables.
71
Table 4. Annual emissions in the production of thermal

energy using coal
2009/10 2008/09 2007/08 The amount of

emitted gas
119 117 106 CO2 [t]
1.249,95 1.235 1.113 CH4 [x 10-6kg]
374.985 370.758 334.119 NOx [x 10-6kg]
24.999 24.717 22.274 CO [x 10-6kg]
1.489.328 1.408.312 1.416.600 SO2 [x 10-6kg]
Table 5. Annual emissions in the production of thermal

energy using coal
Fig.4. The total CO2 emissions [t] produced by burning
2010 2009 2008 The amount of coal and crude oil
emitted gas
167,87 188,99 155,9 CO2 [t] 4. THE PROJECTION OF ENERGY
1.781 2.005 1.655 CH4[x 10-6kg] CONSUMPTION
534.429 601.683 496.443 NOx[x 10-6kg]
35.628 40.112 33.096 CO[x 10-6kg] The document "National cogeneration potential" [11]
2.333.138 2.626.747 2.167.304 SO2[x 10-6kg] drawn up by the Ministry of Economy, Labour and
Entrepreneurship of the Republic of Croatian, served to
Table 6. Annual emissions in the production of thermal propose scenarios for energy development of the Republic
energy using fuel oil of Serbia. The project includes two scenarios for
increasing of final energy consumption, namely: baseline
2009/10 2008/09 2007/08 The amount of emitted and sustainable scenario.
gas The baseline scenario envisages an increase in total final
38 39 41 CO2 [t] energy consumption with an average growth rate of 3%
1.494 1.542 1.586 CH4 [x 10-6kg] per year until 2020, while sustainable scenario of
99.626 102.780 105.730 NOx [x 10-6kg] consumption in all sectors with an average growth rate of
7.742 7.709 7.930 CO [x 10-6kg] 2.7% per year until 2020. The projections of final energy
494.793 510.457 525.108 SO2 [x 10-6kg] consumption to fundamental and sustainable scenario by
energy and energy forms are shown in Tables 8, 9, 10.
Table 7. Annual emissions in the production of thermal and 11 and Figures 5, 6, 7 and 8.
energy using fuel oil
Table 8. Projection of the final energy consumption by
2010 2009 2008 The amount of emitted 2020, the basic scenario
gas
46 48 38 CO2 [t] 2010 2015 2020
All sectors
1.812 1.882 1.500 CH4 [x 10-6kg] TJ
120.818 125.470 100.020 NOx [x 10-6kg] Coal 41871 48540 56271
9.061 9.410 7.502 CO [x 10-6kg] Oil and petroleum
600.043 623.147 496.749 SO2 [x 10-6kg] 114948 133256 154481
products
156819 181796 210752
250000
200000
150000 2010 TJ
2015
100000 2020
50000
Fig.3. The total CO2 emissions [t] produced by burning Fig.5. Projection of the final energy consumption by
coal and crude oil 2020, the basic scenario
72
Table 9. Projected final energy consumption by 2020, the 20000

basic scenario 18000
16000
2010 2015 2020 14000
Households 12000 2010 TJ
TJ
10000 2015
Coal 12434 14414 16710 8000 2020
Oil and 6000
4000
petroleum 1312 1521 1763 2000
products 0

13746 15935 18474
20000
Fig.8. Projection of the final energy consumption
18000
16000
by2020, the sustainable scena
14000
12000 2010 TJ 5. CONCLUSION
10000 2015
8000 2020
As in other European countries, variable fuel prices, as
6000
4000
well as high investment risk are considered major
2000 obstacles to the installation of new cogeneration plants.
0 To facilitate the RS authorities, local governments, the
management of heating-power plant in the RS and

entrepreneurs to make the best possible decisions
regarding the successful redesign of the existing heating-
power plant for their conversion to highly efficient
Fig.6. Projected final energy consumption by 2020, the
cogeneration facilities and/or to build small and micro-
basic scenario
cogeneration units, RS, was made in the context of this
work a detailed analysis of the influence of heating-power
Table 10. Projected final energy consumption by 2020,
plant on the environment. To this end several months of
the sustainable scenario
investigations have been carried out in member states
2010 2015 2020 Business Association of heating plants RS that have
All sectors
TJ allowed to reach a sustainable scenario of mass
Coal 41871 47837 54654 introduction of cogeneration in the RS. The results of this
Oil and petroleum analysis are an integral part of the internet database that
114948 131327 150040 will after completion of the project constitute an
products
156819 179164 204693 important basis for the popularization of application
cogeneration production of heat and electricity
250000
200000 REFERENCES
150000 2010 TJ
[1] Kyoto protocol, United nations framework
2015
100000
convention on climate changes, Kyoto, Japan,
2020
decembar 1997.
50000 [2] COMMISSION DECISION of 21 December 2006
establishing harmonised efficiency reference values
0 for separate production of electricity and heat in

application of Directive 2004/8/EC of the European
Parliament and of the Council (notified under
document number C(2006)6817) (Text with EEA
Fig.7. Projection of the final energy consumption by relevance), (2007/74/EC)
2020, the sustainable scenario [3] Doc. dr in. Milan Despotovi, Prof. dr in. Milun
Babi, Energija biomase', Mainski fakultet,
Table 11. Projected final energy consumption by 2020, Univerzitet u Kragujevcu, Kragujevac, 2007
the sustainable scenario [4] Communication from the commission to the
european council and the european parliament an
2010 2015 2020
Households energy policy for europe, Commission of the EC,
TJ
Brussels, 10.1.2007
Coal 12434 14206 16230
[5] Council Directive 93/76/EEC of September 1993 to
Oil and limit carbon dioxide emissions by improving energy
petroleum 1312 1499 1713 efficiency (SAVE), Official Journal L 237,
products 22/09/1993, pp 0028-0030
13746 15705 17942
73
[6] DIRECTIVE 2004/8/EC OF THE EUROPEAN [9] Miodrag M. Mesarovi, Milan S. alovi, Potencijal
PARLIAMENT AND OF THE COUNCIL of 11 kogeneracije toplotne i elektrine energije u Srbiji,
February 2004 on the promotion of cogeneration TERMOTEHNIKA, 2011, 2, pp 197209.
based on a useful heat demand in the internal energy [10] Predrag LJ. Stefanovi, Zoran J. Markovi, Vukman
market and amending, Directive 92/42/EEC B. Baki, Dejan B. Cvetinovi, Valentina M.
[7] Lonar D et al.: An analysis of the legal and market Turanjanin, Marina P. Jovanovi, Emisija gasova sa
framework for the cogeneration sector in Croatia, efektom staklene bate u toplanama javnih
Energy, Volume 34, 2009, pp 134-143 preduzea daljinskog grejanja u gradovima Srbije,
[8] Minett, S., Cogeneration in Western Europe, TERMOTEHNIKA, 2011, 2, pp 183195.
COGEN Europe Cogeneration Workshop, JRC, [11] Nacionalni potencijal kogeneracije, Ministarstvo
Petten, The Netherland, October 2004 gospodarstva, rada i poduzetnitva, Republika
Hrvatska, rujan, 2008.
74
Research paper
OBTAINNIG THE MAXIMUM LOAD OF THE BENDING LOAD ELEMENT CONSIDERING

THE VARIATION OF THE GEOMETRIC CHARACTERISTIC AND PROPERTY OF THE
MATERIALS
Ilios VILOS1, * - Ljupco TRAJCEVSKI2
1 University St.Kliment Ohridski Bitola, Faculty of Technical Sciences, Bitola, Macedonia
Abstract: The geometric characteristics, the property of the materials which the elements are made of, have more or
less, stochastic character. The issue of safety and reliability of simple bending load element depends on the
characteristics of those parameters. In the first part of this paper the short outline of reliability concept is given. The
second part of this paper gives one numerical example which explains the relation between the appropriate reliability
and the force.
Key words: reliability, bending loaded element
1. INTRODUCTION where A and B are random variables where: A is the

action and B is the resistance . Functions fa(A) and fb(B)
The maximum stress of the bending loaded element are represent the functions of distribution of variables A and
given by the expression: B . A and B represent mean of action and resistance, and
A and B are standard deviation of the action and
M max resistance.
o (1)
W
Where: is the working stress; M is the maximum
working moment; W is the moment of resistance of the
cross section of the element
is maximum allowed stress.
And if the working stress is smaller than allowed stress
we consider that the element is well designed.
The following simple example shows a method to
determine the magnitude of the force depending on the
geometry and material properties which are given whit
its stochastic characteristics. Fig.2. Standard deviation of the action A and resistance B
In this example the magnitude of the force of the simple
single bolt shear loaded connection to ensure the
reliability of 0.99, 0.999 and 0.9999 assuming that the
variation of the force F = 20%,
Fig.3. Highlighted area of standard deviation

Fig.1. Simple beam loaded with force in the middle of the action A and resistance B
Highlighted area on the drawing (Fig.2) represent that the

2. BRIEF REVIEW OF RELIABILITY THEORY resistance is smaller than the action. That is the area
which is characterized by areas of failure.
Reliability as the probability category is determined by If we increase the area that overlaps, given by detail in
the relation: (Fig. 3), and assume that the probability of size A is
D p A B p A B 0 (2) greater than a default argument B0 then:
*Correspondence Authors Address: University St.Kliment Ohridski Bitola, Faculty of Technical Sciences, Makedonska Falanga 33,
7000 Bitola, Macedonia, vilos.ilios@uklo.edu.mk
Ilios Vilos, Ljupco Trajcevski: Obtainning the Maximum Load of the Beding Load Element Considering the Variation of the Geometric
Characteristics and Property of the Materials; Machine Design, Vol.7(2015) No.3, ISSN 1821-1259; pp. 75-78
Where f A, B is density of the distribution of the random

p A B0 f A dA
a (3) variables A and B.
B0
If the random variables A and B have normal (Gaussian)
probability which resistance B has in the interval dB, or distribution then the expression (8) is given by the
more precisely, the probability that belongs to the random expression:
variable B in dB interval is:

A B
dB D (9)
p B B0 f a B0 dB (4) 2 2
A

2 B
B0 is in the middle of the interval dB. If we unite the two Where: A and B are the mean valy of the action and the
conditions (3) and (4) and if we assume that A and B are resistance. A2 and B2 are square of standard deviation of
random variables, We can determine the probability that the action and resistance. is the function which for the
the variable B is in the interval dB while the probability
A B

of the random variable A exceeds probability B0. argument gives the reliability. This function is
2A B2
known as Laplas function.
f b B0 dB f a A dA (5)
B0
From the previous expression reliability D is determined

3. EXAMPLE
by the probability of A size exceeds the size B for all
possible values of B. To determine the magnitude of the force of the simple
single bending loaded element (Fig. 1) and to ensure the
D

f b ( B) f a ( A)dA dB

(6) reliability for default value we start from the expression
B (9)
Geometrical expression of the relation (6) is given in the

following figure: A B
D (10)
2 2
A B
To determine the value of the force P = ? Which for the

bending loaded element will provide reliability of: a)
0.99 b) 0.999 c) 0.9999 if the item is I 100 hot rolled
steel beam with variation in force = 20 % (0.2).
Data on the mechanical characteristics of the material and
geometric characteristics of the cross section are taken
from the survey [3] and are:
Figure 4 . Geometrical expression of the relation (6) Average value on resistance point of intersection W =
34.294 sm3
Similar to the expression (6) we have Average square deviation of the resistance point w =
0.991 sm3
f a ( A) b f B dB dA
A
D (7) Average value of the critical stretch stress A = 38.09

KN/sm2
Geometrical expression of the relation (7) is given in the Average square deviation of critical folding stress w =
following figure: 2.556 KN/sm2
Distribution of all random values is normal. Adopted
random values are: the force P, resistant moment of cross
section and folding stress. We are starting from the
relation (8):

A B
D (8)
2 2
A B
Where: is the average value of the resistance, in this

Figure 5. Geometrical expression of the relation (7)
case average value of critical stretch stress -
If the variables A and B can be described by mathematical 38.09 ; is the average value of the action, in this
expression then reliability can be express as: case action is the working stress, i.e
M Pl l
D

f A, B dAdB B P (11)

B
(8) W 4W 4W
76
Where: a is average square deviation of critical folding With replacing all known variables and expressions (10)
stress a = 2.556 KN/sm2 ; a is average square deviation and (14) in the relation (8) we have:
of the working stress.
Working stress for a simple beam loaded with

lP
concentrated force in the middle is: W
M Pl D 4W (16)
Working stress = 2 2
W 4W l 2 l 2
A P G P
2 P W

and in this case represents function of two random 4W 4W
variables, the force P and resistance moment of the cross
Where the only unknown force is the force P.
section W. From [5] [4] we know that average square
For the reliability of D = 0.99 from the table (Table 1) for
deviation of the function with two or more random
the values of the function of normal distribution the index
variables is this:
of reliability has value 2.33. For D = 0.999 the index of
f
2 reliability has value 3.1. For D = 0.9999 the index of
n
y | x x x2i (12) reliability has value 3.75.
i 1 xi For D = 0.99 and = 0.2, we have:

200
From the expression (12) follows that the inference 38.09 P
should be calculated from expression for the working 2.33 434.294
2 2
stress (11) with first random variable i.e. with the force P 200 0.2 2 200 0.991 2
2.5562 P P
and than the square of that inference should be multiplied 434.294 4 34.294
with the square of the average square deviation of the
force P. After the calculations we have:
Then, again calculation should be made with the inference
of the expression for working stress (11) with second 1.65452 P 2 111.07044 P 1415.38110 0
random variable and diameter d. Finnaly, the square from
the last inference should be multiplied with the average P 17.096 kN
square deviation of the diameter d.
The Table 1 shows variation of the force, reliability,
2 2
Pl Pl expression from which force is obtained, force for the

2
P2 W2 (13)
B
P 4W W W W 4W W W wanted reliability and safety factor .
Than we have: Table 1. Variation of the force, reliability, expression

from which force is obtained, force for the wanted
Pl l reliability and safety factor .

P 4W W W 4W Force
Vari for
Safet
ation Rel the
Pl Pl y
2
of iabi Expression from which force is obtained wante
facto
W 4W W W the lity d
r
4W force reliab
ility
If these expressions are substituted in the expression (13),
0.9 1.654 111.07 P 1415.381 17.09 1.52
we will have the following expression: 9 0 6 8
2
2 Pl
2
l
B2 P W2 (14) 20% 0.9 1.291 P 111.07 P 1388.066 15.17 1.72
2 (0.2) 99 0 5 1
4W 4W
We dont know the average square deviation of the force, 0.9 0.924 P 111.07 P 1360.442 13.99 1.86
so we use the variation of the force and we have the 999 0 6 6
following expression:
P Safety factor it is obtained from the relationship
P P P P
P between boundary force and the force given for the
wanted reliability. The boundary force is obtained from
If we replace obtained expression in expression (14) we the expression (10):
have the following expression:
4W boundary 4 34.294 38.09
2 P 26.125 kN
2 l
2
l l 200
B2 P P W2 P2 (15)
Where indicates the stretching)
4W 4W
77
REFERENCES
[1] .., ..,

, 1985
[2] Anii D., Probablistiki pristup proraunu graninih
stanja za zidane konstrukcije, Graevinar 39, 1987 g,
str.393-401
[3] Fred Moses, Design of reliability Concepts and
Aplication, Ch.13, Optimum Structural Design JOHN
Wiley&So.1977
[4] Ivanovi G., Pouzdanost tehnickih sistema, Zbirka
reenih zadataka,Mainski fakultet Beograd, 1987 g.
[5] Ronald R. Graham, Donald E. Knut, Oren Patashnik,
Concrete Mathemathics: A foundation for computer
science 1994
Fig.6.Geometric presentation of the obtained force for [6] John A. Rise, Mathematical Statistics and Data
different reliabilities Analisys, 2007
4. CONCLUSION
This paper has shown mathematical model to take into

account the impact of the reliability factors and how to
design the bending loaded element with default
reliability.
78
Research paper
CONSTRUCTION SOLUTION AND ESTIMATE OF IMPORTANT ELEMENTS

ASSEMBLIES OF LOG SPLITTER
Milan TICA1, * - Branislav OLI1 - Slobodan APLJAK1
1 University of Banja Luka, Faculty of Mechanical Engineering, Banja Luka, B&H
Abstract: A construction solution of log splitter is developed using methods of modern developed of products.
Developed construction solution is optimal from an economic and technical aspects. The results are displayed and
constructional solutions of all assemblies and subassemblies of log splitter. Important functional elements and
subassemblies are identified. A software package Solid Works was used for modeling and calculations. Calculation and
analysis of important functional subassemblies and components was used for the optimization of measuring and testing
load. The technical documentation is made and the next step should be a prototype development
Key words: construction solution, wood splitter, estimate
1. INTRODUCTION structure of parts from which the system will consist. The
dimensioning and shaping of machine parts is done in a
Analysis of the market, product price and customer target third phase.Adequate materials and methods of making
group was followed by the conception of conceptual are chosen for each part of the machine. The fourth
design. Answer to the question How? (in which phase includes examination of stress state, safety and
principles of mechanical system will perform its function) reliability, etc. The fifth phaseof the design process
is obtained by creating conceptual design of mechanical includes structural development. Here are made drawings
systems. In the first phase (in the abstract form) of of details, prescribed tolerances, thermal treatment, etc.
construction was determined what mechanical system
needs to do and what conditions should it meet. At this
stage, the answer to the question of how it works is given.
The main function of log splitter is to achieve a sufficient
compressive force on the blade to allow the parting of the
log. The condition that log splitter needs to fulfill is to be
able to split logs in diameter of 60cm and a maximum
length of 110cm. Speed of the blade must be adequate so
that the splitter have a satisfactory productivity, but the
speed shouldn't be too high to endanger controllability.
The idea is that the wood splitter should allow
installation in two positions, both vertical and horizontal.
Analysis showed that the best option is to use tractor
engine to drive machinery for the transfer of power
should be used hydraulic pump. Hydraulic cylinder with
axe blade should be controlled by control unit. All of the
mechanical assemblies must be properly sized to
withstand all possible stresses (both during operation and
during transport), because we need to provide a long-time
and safe operation of log splitter.
The first phase includes the development of ideas and
data collection in order to define the conditions that the
mechanical system should meet. These conditions Fig.1. The flow chart of the process of constructing
(requirements and desires) are the result of the current
market, customers and manufacturing capabilities. The The first phase includes the development of ideas and
second phase in the design process provides an answer to data collection in order to define the conditions that the
the question on which the principle of mechanical system mechanical system should meet. These conditions
will work. This is the design principles of operation and (requirements and desires) are the result of the current
*Correspondence Authors Address: University of Banja Luka, Faculty of Mechanical Engineering, Vojvode Stepe Stepanovia 71,
78000 Banja Luka, Republika Srpska, B&H, mtica@blic.net
Milan Tica, Branislav oli, Slobodan apljak: Construction Solution and Estimate of Important Elements Assemblies of Log Splitter;
Machine Design, Vol.7(2015) No.3, ISSN 1821-1259; pp. 79-84
market, customers and manufacturing capabilities. The well as the stability of the log during operation. The base
second phase in the design process provides an answer to is designed in such way to be as simple for production.
the question on which the principle of mechanical system The base and support pillar are joined by welding and
will work. This is the design principles of operation and with screws.
structure of parts from which the system will consist. The In addition to these functions, base serves for the closing
dimensioning and shaping of machine parts is done in a of forces circle during splitting of the log, so it must
third phase.Adequate materials and methods of making endure high pressures.
are chosen for each part of the machine. The fourth phase
includes examination of stress state, safety and reliability,
etc. The fifth phaseof the design process includes
structural development. Here are made drawings of
details, prescribed tolerances, thermal treatment, etc.
2. CONSTRUCTION SOLUTION OF WOOD

SPLITTER
applying the methods of modern product development a

structural solution for log splitter is developed (Fig.2).
Wood splitter assembly consists of the following
subassemblies:
Base,
Blade,
Hydraulics cylinder, Fig.3. Scheme of Base
Oil tank,
Supporting pilar and Blade is sized and shaped to allow penetration into the
Hydraulics system. wood with the smallest force. The angle of the cutting
edge is designed to keep sharpness for a long time.
Horizontal arched groove is making contact with log and
enables easier splitting of the wood. The blade is
connected to the piston rod by screw which converts
torque into axial loads. Torque occurs due to irregularity
in shape of wood.
Fig.2. Conceptual sheme of the splitter
2.1. Functional analysis of subassemblies

Subassemblies of the log splitter constitute a functional
unit that must enable performing all the required function
of the log splitter. For this reason, subassemblies of the
log splitter are designed and selected to provide long-time
exploitation.
Base (Fig. 3) of log splitter must be dimensioned in such
a way to ensure the stability of the machines at work, as Fig.4. Blade
80
The slider allows translational movements of the blade a very important function in the assembly of the log
and prevents excessive bending of the piston rod of the splitter. It is designed and dimensioned to withstand high
hydraulics cylinder. The slider is dimensioned so that dynamic loads. It is a attached to a supporting pillar by
there is adequate clearance between the slider and the welding, and connected with reservoir by screws.
surface of the basic structure on which the slider moves. Due to the large loads on the connecting element leads to
Gutter of the slider is made from two sheet metal peaces high stresses in the materials, it is strengthened with
which are connected with the screws. The slider is additional sheets of high strength. Thermal processing is
dimensioned to enable its sliding without the possibility necessary to increase shock resistance.
of jamming.
Fig.5. Slider
Bracket for central lever of tractor is multifunctional and

it serves as a reservoir for storing of the hydraulic oil that
supplies hydraulic system. Carrier is made using
technology of bending sheet metal, and it is fixed to the
support pillar using bolts and welds through. The carrier
has sufficient strength to resist from bending when the log
splitter is being transported in a horizontal position.
Fuel cap is located at an appropriate position to avoid
spillage of fluids when the log splitter is used in
horizontal position.
Fig.7. Holder for hand
Fig.6. Reservoir with fuel cap
Handle is made from standard tubular profiles and

attached to the basic structure by screws. Handle provides
good grip for the operator during operation, and moving
the handle to another position serves as the delimiter for
wood (in a horizontal position).
The connection element (which is prismatic shape)
between the cylinders, reservoir and supporting pillar, has Fig.8. The connecting element
81
On the basis of the calculations adopted by the hydraulic

cylinder manufacturers PRVA PETOLETKA -
TRSTENIK, in standard sizes and shapes.
Fig.10. Scheme of the cylinder
The oil flow through the system
Input data:
Speed of the blade: v=10 cm/s
Number of revolutions on the output shaft of tractor:
n=1000 o/min
Based on the speed of the bladev, required oil

flowQthrough the system is calculated.
Q v A
Fig.9. Log spliter
cm 3
Q 76320
3. CALCULATION OF IMPORTANT min
ASSEMBLIES
Q oil flow in the system
3.1. Calculation for hydraulics system
Calculation of hydraulic pumps
Since it is assumed that the drive machine is the engine of
the tractor, which uses hydraulic pump as power Q
transmitter, the next step was to calculate and construct a V pump 73, 620 cm3
n
hydraulic system.
The input data for the hydraulic system are pressure (that
blade makes to the log), speed of the blade and maximum
stroke of the piston rod.
Input data:
The power that the blade should achieve: F 20 t
Speed of the blade: from 10 cm/s to 20 cm/s
The pressure in the system: p 160 bar
The value of pressure in the hydraulic system is
p 160 bar adopted with respect to existing solutions
from competing producers.
Fig.11. Cheme of pumps
Sizing hydraulic cylinder
The pump with following tags is adopted :3115.481.19M,
F p A p-pressure; A-area displacement, manufacturer PRVA PETOLETKA
TRSTENIK.
F
A
p The actual speed of the blade at 1000 o/min :
D 2
A
4 Q
V 9.05 cm
4 F A s
D 124.9 mm
p
The actual speed of the blade at 1500 o/min :
D diameter of piston
82
Q Minimum value of hose diameter is calculated from

V 13.58 cm Rennolds number equation, to maintain the lamellar flow
A s
Feed speed of the blade: of fluid in the hose andat the same time to reduce line
losses.
Q 4Q
V 28.87 cm Re
Apiston ring s d
4Q
Calculationsfor the distribution valve d
Re
Input data:
Since the value of Renolds number must beless than 2000
l (Re 2000) follow:
The oil flow through the system: Q 66.66
min
The pressure in the piston chamber: p 160bar d 15.36 mm d diameter of hose
The pressure in the connecting rod: 58.25 bar Adopted diameter of the hose: d 16 mm tags 2ST DIN
Control valve (tags: RPR3-06 / J15, manufacturers EN 853 SEA100 R2A, manufacturer
l CENTRALINVEST. The hose has an inner diameter
ARGO HYTOS with maximum flow Q 80 is
min d 15.9 mm , submitted a working pressure up to
adopted.
Flow resistance and pressure drop are calculate using p 250 bar and haveminimum bending radius
diagrams. dbending 200 mm .
Choice of hydraulic oils

For the known kinematic viscosity from the previous
calculations, in order to achieve laminar flow, which
corresponds to the all components of the hydraulic
system,oiltype MH-46 (manufacturer RAFINERIJA
ULJA MODRIA) is chosen.
Selection valve for limiting pressure
From the catalog PRVA PETOLETKA TRSTENIK
activation safety valve is selected ( valve type: 127.842-
02. This valve is adjusted to the pressure of activation
p 180 bar . In the event of excessive pressure in the
Fig.12. Pressure drop related to flow rate working stroke, valve regulates the pressure in the
hydraulic system and prevents exceeding the maximum
The pressure drop: p 11 bar pressure and any possibility of system failure.
The pressure in the return line is limited by the safety
The maximum pressure in the system: valve (valve type:127.842-01 selected from the same
pMAX p p 160 11 171 bar . catalog) is adjusted to p 59 bar .
The safety valve is set at the maximum pressure value and

the certain value is added due to the existence of linear
and local losses:
pMAX 180 bar .
Valve for pressure relief is adjusted in the starting

position to:
prelieve 58.25 bar .
Calculation for hydraulic hoses in the system
Input data:
The oil flow through the system: Q 66.66 l
min
Start viscosity of the oil: 46 mm

2
s Fig.13. Scheme of hydraulics system

83
3.2. Calculations of capacity The connecting element is dimensioned to withstand high

dynamic loads and to transfer them to a supporting pillar.
Stresses in machine parts are the main indicator of the Due to the large loads on the connecting element leads to
mechanical state. Stress and stress changes are the main high stresses in the materials, it is strengthened with
cause of fatigue of the material structure of mechanical additional sheets of high strength. Thermal processing is
parts, the formation of cracks and fractures. The most necessary to increase shock resistance.
important criterium for determining the dimensions of
mechanical parts used criterium of strength.Stresses are
the most importantboundary condition for optimizing the
shape of the mechanical parts.They are the primary factor
in determining the reliability of mechanical parts and
systems, in determining lifetime, load, etc.
Bearing capacity of important elements is calculated in
the software package Solid Works in module Simulation
Xpress which is based on the FEM (Finite Element
Method).
The software analysis enabled selection of adequate
materials for all elements. The points of maximum loads
are identified,and the values of these maximum loads are
calculated. Analysis of the essential elements of the
assembly of the log splitter is shown below. Fig.16. The connecting element - SimulationXpress Study
Stress
4. CONCLUSION
Construction of machines includes the methodology of

transformation achieved level of scientific and technical
knowledge in the technical or mechanical system.A
construction solution of log splitter is developed using
methods ofmodern developed of products. The process of
designing, calculation of important elements of the system
and an analysis of the mechanical parts is showed belowe.
A software package SolidWorks was used for modeling
and calculations.
Calculation and analysis of important functional
subassemblies and components was used for the
optimization of measuring and testing load.The technical
documentation is made and the next step should be a
prototype development.
Fig.14. I PROFILE SimulationXpress Study Stress
REFERENCES
[1] Miltenovi V., (2003.). Razvoj proizvoda - strategije,

metode, primena. Univerzitet u Niu, Mainski
fakultet, Ni.
[2] Milan Tica, Vojislav Miltenovi, Milosavurevi,
Razvojsistemazapresovanjedrvnogotpadaprimjenomm
etode TRIZ sistematsko traenje rjeenja,
etvrtisimpozijumsameunarodnimueemKONSTR
UISANJE, OBLIKOVANJE I DIZAJN 2006, 30 - 31.
maj 2006, Pali,Zbornikradova str. 365-370.
[3] Ognjenovi M., (2000.). Konstruisanje maina,
Univerzitet u Beogradu, Mainski fakultet, ISBN 86-
7083-398-1, Beograd.
[4] Tica, M.: The use of evolutionary principles and
Altschuller matrixes in determination of direction of
further lumber scraps pelleting system development,
FactaUniversitatis, Series:Mechanical Engineering,
Fig.15. I PROFILESimulationXpress Study Displacement 2006,
[5] M. Tica, M. urevi, Theoretical analysis of the
This simulation shows the stresses and deformations of dominant construction-technolological parameters of
the main supporting pilar. Dimensions of the supporting the lumber scrap pelleting systems from the aspect of
pilar are in adequate size so the stress do not exceed the the optimal main function of the system, Machine
critical values for dynamic loading of adopted materials. Design, May 18th 2007., str. 435-438.
84
Research paper
END-MILLING FORCE CONTROL SYSTEM WITH SURFACE ROUGHNESS MONITORING

Uros ZUPERL 1*, - Franc CUS 1
1 University of Maribor, Faculty of Mechanical Engineering, Maribor, Slovenia
Abstract: The aim of this paper is to present an adaptive force regulation system in end milling with the newly
developed surface roughness prediction model. The relations between measured cutting force, cutting conditions and
actual surface roughness of machined surface were determined via adaptive neuro-fuzzy inference modeling (ANFIS).
The trained ANFIS model predicts the effect of machining parameters and maximal cutting force on surface roughness
during machining. End milling machining process of hardened die steel with carbide end mill was used for modeling.
The developed model monitors the actual surface roughness and in case of excessive value provides warnings to the
operator or stops the machining process for tool change.
Key words: milling, adaptive control, monitoring, surface roughness, prediction, ANFIS.
1. INTRODUCTION process method based on prediction model is required for

the real time process monitoring. We attempt to solve this
Despite many research, there are no available method for situation by employing the ANFIS to predict the surface
monitoring surface roughness in high-speed end-milling. roughness based on measured cutting forces and to CNC
In milling the relationship between process characteristics controller sent cutting conditions. A new surface
and surface roughness is difficult to capture. This is due roughness prediction model is integrated with the existing
to the complexity of the relationship between surface cutting force control system. The traditional ability of the
roughness and process characteristics. Therefore, an in- operator to determine the quality of the machined surface
Constraints
F < Fmax, Recommended

fmin < f < fmax, cutting
nmi < n < nmax conditions
ADmin < RD < ADmax
RDmin < RD< RDmax
n, f, AD,RD
n, f, AD,RD
Surface Ra Surface
roughness
roughness Ra
tester
prediction
model
n, f, AD,RD Surface roughness
tester
(ANFIS)
Fref Adaptive fc CNC F
Milling
force controller Dynamometer
Fagor 8040-M
process
controller
F
Milling process Dynamometer
Cutting force control
Fig.1. Inclusion of ANFIS predication model in the adaptive force control system.
based on his experiences and senses is now the expected based on the least-squares regression for estimating
role of the predictive model in the upgraded system. surface roughness in machining while [3] have,
Several other models have been proposed to estimate the respectively, used fuzzy pattern recognition for
surface roughness. These include classical statistical monitoring surface roughness over a limited range of
approaches as well as fuzzy systems and neural networks. cutting conditions. The capacity of artificial neural
For instance researchers [1,2] developed an approach networks to capture nonlinear relationships in a relatively
*Correspondence Authors Address: University of Maribor, Faculty of Mechanical Engineering, Smetanova 17, 2000 Maribor,
Slovenia, uros.zuperl@um.si
Uros Zuperl, Franc Cus: End-Milling Force Control System With Surface Roughness Monitoring;
efficient manner has motivated a number of researchers to additional level of transparency that neural networks fails
pursue the use of these networks in developing surface to provide.
roughness prediction models. But in these models, the
nonlinear relationship between sensor readings and 2. ADAPTIVE CUTTING FORCE CONTROL
surface roughness embedded in a neural network remains STRUCTURE
hidden and inaccessible to the user [4]. In this research
we attempt to solve this situation by using the ANFIS The adaptive control system shown in Fig. 1 is a
system to predict the surface roughness. cutting force feedback loop where the feedrate adjusts
This model offers ability to estimate surface roughness as itself to the actual cutting force F, and varies according to
its neural network based counterpart but provides an the changes in work conditions during machining.
2
Experimental work Define ANFIS
Cutting conditions
f, RD, AD, n Measured
Generate initial FIS model
surafece
roughnes
Measured cutting Ra
Set initial input parameters
force F
and membership function
Load training and testing data Chose optimization method

matrix (hybrid method)
Load data
Divide matrix to Input and Output Define the maximum training/

vector testing epochs
ANFIS training
on?
3 yes
no 4
Model developing
Model developing
Model testing ?
Input Training data into ANFIS

system
no yes
Input Testing data into ANFIS no

Model system
trained?
yes View FIS structure, output surface

of FIS, generated rules and
Developed ANFIS model adjusted membership functions
Model employing
Model developing
5
Get results after training, Get results after testing,
plot results plot results
Fig.2. Algorithm for training and employing the surface roughness model
The actual maximal cutting force is sampled every 0.01 The controller adjusts the federate override percentage
seconds and converted to a digital signal. This signal is and sends the determined federate command signal to the
immediately compared with a predetermined reference federate routine in the CNC controller. A positive error
cutting force Fref. The maximum measured force is a increases the programmed feedrate and consequently
good starting value for the reference force Fref. The increases the produced actual cutting force. A negative
difference between the F and Fref is the control error. The error decreases the programmed feedrate and
control error is used as the input to the system controller. consequently decreases the actual cutting force. The
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controller is connected with the CNC controller of a 4-

axis machining center, as shown in Fig. 1.
The federate control is achieved through Feed override
commands. In order for the controller to regulate peak
force, force information must be available to the control
algorithm at every 20ms. Data acquisition software
(LabVIEW) and the algorithm for processing the cutting
forces are used to provide this information. When the
adaptive controller is turned on, the feedrates generated
by the CNC controller are sent to the feed drive servo-unit
and the surface roughness prediction model.
This model predicts surface roughness on-line and
displays the value to the operator. If the value of the
surface roughness exceeds the predetermined limits, the
warning message is sent to the operator.
3. ANFIS SURFACE ROUGHNESS MODEL
The aim of this study is to develop an accurate and Fig.3. Architecture of ANFIS surface roughness model
reliable model for predicting surface roughness during
end milling process. The surface roughness prediction structure to give correct output results according to the
model is built according to the ANFIS method. The input features. The process is terminated when the error
ANFIS method seeks to provide a linguistic model for the becomes less than the threshold value.
prediction of surface roughness from the knowledge During training in ANFIS, 350 sets of experimental data
embedded in the trained neural network. By given are used to conduct 500 cycles of learning. Finally, in the
input/output data set, the ANFIS method constructs a fourth step the trained ANFIS is used to predict surface
fuzzy inference system (FIS) whose membership function roughness. After the training, the inference system could
parameters are tuned (adjusted) using a backpropagation estimate surface roughness from cutting force
algorithm. This allows fuzzy systems to learn from the measurement and cutting conditions in real time.
data they are modeling. FIS Structure is a network-type The developed ANFIS model can guide system or
structure similar to that of a neural network, which maps operator in tool change decisions making.
inputs through input membership functions and associated
parameters, and then through output membership 4. EXPERIMENTAL SET-UP
functions and associated parameters to outputs. Fig. 2
shows the basic flow chart for predicting the surface Experiments were performed on a CNC machining
roughness via ANFIS. platform Heller with FAGOR CNC controller. Material
Five steps are required to develop an ANFIS system. In Ck 45 and Ck 45 (XM) with improved machining
step 1, the training and testing data are loaded to the properties were used for tests.
system. The process variables are force sensor readings The solid end milling cutter (R216.24-16050 IAK32P)
(F), spindle speed (n), feed rate (f), depth of cutting with four cutting edges, of 16 mm diameter and 10 helix
(AD/RD), and measured surface roughness. All the data angle was selected for machining.
were scaled. The whole data set is divided into the The corner radius of the cutter is 4 mm. The cutter is
training and the testing set. 350 data points were used in made of ultra-fine carbide grade coated with TiN/TiCN
this study. The training data set is used to find the initial coating.
premise parameters for the membership functions by The coolant RENUS FFM was used for cooling. The
equally spacing each of the membership functions. A cutting forces were measured with a piezoelectric
threshold value for the error between the actual and dynamometer (Kistler 9255) mounted between the
desired output is determined. workpiece and the machining table.
The FIS architecture and training parameters were defined The data acquisition package used was LabVIEW. The
in step 2. The optimization method, the tolerance error, surface roughness was measured by 7061 MarSurf PS1
the maximal number of epoch, the number of membership Surface Roughness Tester. The experimental set up can
functions and the membership functions types are defined. be seen in Fig. 4.
The ANFIS architecture is explained in detail in [5]. The experiments were carried out for all combinations of
The fuzzy inference system under consideration has 5 the chosen parameters [6], which are radial/axial depth of
inputs and one output. The inputs are cutting force sensor cut, feedrate, spindle speed and tool wear. Other
signal, and the cutting conditions. The output is surface parameters such as tool diameter, rake angle, etc. are kept
roughness provided by the surface roughness tester. In constant. Three values for the radial/axial depth of cut
step 3, the training phase is accomplished. With the have been selected for use in the experiments: RD1 = 1d,
inputoutput data, the neuro-fuzzy algorithm is trained, RD2=0.5d, RD3=0.25d; AD1 = 2mm, AD2=4mm,
and the unknown parameters are identified. AD3=8mm; d- cutting parameter (16 mm). In the
Fig. 3 shows the inputs, membership functions, and the experiments the following values for feedrate and spindle
fuzzy inference system for surface roughness prediction. speed were varied in the ranges from 0.05-0.6 mm/tooth
During the training stage, the ANFIS adjusts its internal and 125 350 min-1, respectively. In this way two sets of
87
data groups were generated, one for training and other for were obtained when triangular membership functions
testing. were chosen for the neuro-fuzzy model.
The cutting force signals were monitored by using a fast The average error of the prediction of surface roughness
data acquisition card (National Instruments NI 9215 A) is around 2.9% when triangular membership function is
and software written with the National Instruments CVI
programming package. used in ANFIS. The accuracy is as high as 96%. The
training was very fast, and the error reached a constant
5. RESULTS AND DISCUSSION value after about 45 epochs. In this case, there were 36
rules in the fuzzy inference system.
Predicted surface roughness was found significantly The system with incorporated ANFIS model was capable
sensitive to the measured cutting forces, especially the of predicting the surface roughness in real time.
thrust cutting component. A total of 250 sets of data were The accuracy of the training data was 98.1%, and the
selected from the total of 350 sets obtained in the end accuracy of the testing data was 96 %. Wrong predictions
milling experiments [5] for the purpose of training in accrued when the feed rate and rotational speed were low.
ANFIS. The other 100 sets were then used for testing This issue can change the cutting forces and affect the
after the training was completed to verify the accuracy of tool wear estimation via force signals. The force sensor
the predicted values of surface roughness. The best results gives a good estimation of the surface roughness.
1000
800 Fx
600
Fy
Fz
400
200
-200
-400
Fig.4. Experimental set up for surface roughness modeling
6. CONCLUSION milling. International Journal of Machine Tools and

Manufacture, Vol. 46, pp. 1395-1402.
The purpose of this research was to integrate the surface [2] Zeroudi, N. & Fontaine, M. (2012). Prediction of
roughness prediction model into the control system aimed Machined Surface Geometry Based on Analytical
at controlling the cutting force by digital adaptation of Modelling of Ball-end Milling. Procedia CIRP, Vol. 1,
cutting parameters. The presented ANFIS model predicts pp. 108-113.
surface roughness with 96% accuracy. It is important part [3] Alauddin, M.; El Baradie, M.A. & Hashmi, M.S.J.
of cutting force control system. Surface roughness was (1995). Computer-aided analysis of a surface-
measured after each cutting test with a Surface roughness roughness model for end milling. J. Mater. Process.
tester. Comparison between the actual surface roughness Technol., Vol. 55, pp. 123-127.
and the simulated results from the neuro-fuzzy method [4] Sokolowski, A. (2004). On some aspects of fuzzy logic
showed good agreement. Once the ANFIS model was application in machine monitoring. Engineering
trained the surface roughness can be displayed to the Applications of Artificial Intelligence, Vol.17, pp. 429-437.
operator on the control panel. In this way it provides [5] Dong, M. & Wang, N. (2011). Adaptive network-
additional level of process monitoring. based fuzzy inference system with leave-one-out
The efficiency of the control system with integrated cross-validation approach for prediction of surface
ANFIS model is reflected in improved surface quality. roughness. Applied Mathematical Modelling, Vol. 35,
No. 3, pp. 12-18.
REFERENCES [6] Cus, F. & Balic, J. (2000). Selection of Cutting
Conditions and Tool Flow in Flexible Manufacturing
[1] Ozcelik, B. & Bayramoglu, M. (2006). The statistical System. The International Journal for Manufacturing
modeling of surface roughness in high-speed flat end Science & Technology, Vol. 2, pp. 101-106.
88
Research paper
APPLICATION DEVELOPMENT FOR LEARNING ABOUT GRAPHIC SYSTEMS

INTEGRATED IN THE PLATFORM OF E-LEARNING
Dragoljub NOVAKOVI1, * - Stefan UREVI1 - Ivan PINJER1 - eljko ZELJKOVI1 - Nemanja KAIKOVI1
1 University of Novi sad, Faculty of Technical Sciences, Novi Sad, Serbia
Abstract: This paper presents a segment of the research focused on developed applications for all graphic systems
(prepress, press and postpress), within the developing platform for learning about them. A simple application user
interface makes it easier to communicate with the user and increases the interest in learning. In order to save
resources, prevent of workplace injuries, save equipment damage by inexperienced users and save time spent on
machine training applications are made for a large number of graphic systems. This paper presents a segment of
developed applications for graphics systems Riso EZ570, KBA Rapida 7 and Horizon AFC-544AKT. The aim of the
research is to analyze the process of developing applications for distance learning in the graphic systems and
possibilities for their improvement.
Key words: graphic systems, applications, e-learning
1. INTRODUCTION Tutorials + +
Initial ideas for the development of a platform for Texts for reading + +
distance learning were inspired by the desire to overcome
the physical distance for the sake of knowledge transfer. Multimedia materials +
Overcoming the traditional method of learning is largely
aided by the development of the Internet. Internet A list of additional
+ +
technology is the key to the revolution in learning, but by resources for learning
itself it cannot improve the quality of learning. In this
regard, the development of distance learning is rapidly Unlimited reviewing
+
supported by scientific research, particularly by the work
faculty. The conclusions of these studies are as follows, Quizzes and other
distance education (e-learning) offers numerous materials to test
advantages (Table 1) but was unable to overcome its +
achievement in each
limitations. In these constraints primarily counted to e- area
learning from the user requires certain skills and Projects and seminar
possession of equipment that the equipment can fail at + +
papers
any time and interrupt the educational process, students Location for learning
need to motivate themselves for learning, etc. +
on the Internet
E- Traditional Currently available
The possibilities +
Learning learning results
Glossary and
Independence from databases of
+ +
places of learning frequently asked
Independence of time questions
+
of learning
Diploma of completed
The possibility of self- + +
education
organization of +
learning time
Discussions with other Those who believe that technology will completely
+ replace the great teachers in the classroom and motivated
students
students in front of them, instructors who train employees
Consultation
on machines were mistaken as well as those who believe
regardless of the +
that learning via the Internet is passing trend [1]. Learning
distance
is a continuous cultural process, not just a series of events.
Technical Support + + The idea that is learning relocated from classrooms and
*Correspondence Authors Address: University of Novi sad, Faculty of Technical Sciences, Trg Dositeja Obradovica 6, 21000 Novi
Sad, Serbia, novakd@uns.ac.rs
Dragoljub Novakovi, Stefan urevi, Ivan Pinjer, eljko Zeljkovi, Nemanja Kaikovi: Application Development for Learning About
Graphic Systems Integrated in the Platform of E-Learning; Machine Design, Vol.7(20150) No.3, ISSN 1821-1259; pp. 89-92
laboratories in the new digital work environment provides assignments, quizzes, lessons, databases, dictionaries,
a new opportunity to make learning accessible to anyone, etc.) to support teaching and learning, but what
anytime and anywhere. Such organized learning gives the distinguishes the work with it over the traditional method
importance of learning outside of formal learning of learning is to explore possibilities of computers to
programs, encourage the development and improvement integrate multimedia content. Creating multimedia
of multimedia materials in these platforms. elements is a very powerful concept, but it is not possible
using Moodle, so when it comes to the use of multimedia
2. E-LEARNING IN GRAPHIC INDUSTRY content in Moodle it mainly referring to the creation of
multimedia using other software tools and then the
integration of multimedia into Moodle. [4]
Employees in graphic or any other industry want and need
to learn according to their schedule. They want to learn as
quickly as possible. Learning must be fully accessible, 4. MULTIMEDIA IN MOODLE
with the possibility of knowledge transfer in plants,
offices, homes, hotel rooms, etc. [2]. With new Integration of text, images, audio and video within a
technologies, this can be achieved and thus save single medium represents multimedia. The emergence of
downtime of machines for training and increase the multimedia refers to the period of development of
organizational mobility. Some of the operators would like computer technology before the invention of the Internet,
to learn slowly, a little bit every week or when their but the Internet began a real revolution in the application
schedule allows. While still training in real systems in real and method of generating multimedia content. Sharing
laboratories play an important role in the education of the multimedia content over the Internet was initially
employees, the needs of employees who have different represented a considerable effort, because of limitations in
requirements for learning can be efficiently fulfilled by the share of information through the Internet. Multimedia
combining them with new technology learning, e- as a combination of multiple media in one uses a larger
learning. space in the computer's memory, but with today's
One of the most important strategies for management of technological capabilities, fast Internet, this limitation
modern enterprises is improving the knowledge and skills increasingly losing importance.
of engineers through frequent training and exercises. Creating multimedia for learning about graphic systems is
If graphic company expect from a leading engineering to based on the use of software tools Adobe Flash, and 3D
often devote time to training or teach other employees and Max.
prepare materials for presentations, it will remain less
time that they engage themselves in the production 5. THE VIRTUAL ENVIRONMENT
process. Their participation decrease in the educational
process of operators and increase of the quality of training The graphic interface (system of software components
materials can reduce costs and increase the productivity of icons, menus, command line) is an essential part of
the graphic company. communication between users and applications of
Results of experiments showed that a new approach to graphics systems. In addition to the graphical interface,
learning can help experienced engineers to efficiently the application includes a virtual environment. "Virtual
create high-quality courses for e-learning, and therefore environment" is a teaching environment located in
inexperienced engineers can be in step with the times to computer-generated and supported communication
get fresh information about advanced technologies and systems, consisting a set of communication groups, work
obtain the required knowledge. spaces and rooms that have been built [5].
There are different systems for managing e-learning:
WiZiQ, Moodle, ATutor, Blasckboard, and others. 5.1. The virtual environment of graphics laboratory
For the purpose of creating an e-learning system and training for With the careful development of multimodal interactive
operators in the graphic industry after viewing educational
platforms and their opportunities, it was chosen Moodle
interface, it is possible to offer a new graphical interface
platform [3]. with the 3D environment. Figure 1 shows the segment of
virtual laboratories with graphic machines.
3. MOODLE PLATFORM
Moodle (Modular Object-Oriented Dynamic Learning

Environment) is one of the most popular and most used
open source system for controlling Distance Learning
(Learning Management System - LMS).
LMS is a set of standardized components for learning,
designed so as to connect learning with existing IT
systems within an organization or through a portal for
learning. The aim of the LMS is to provide in a short
period a centralized learning environment via a computer
that does not depend on the geographical relocation of Fig.1. Segment of virtual graphic machines
users, their previous knowledge or position in the
company. Moodle is available from many sources Modern 3D technology solutions provide the ability to
(websites, books, files, links, etc.) and activities (forums, move and explore space, without direct presence with a
90
searchable knowledge base of graphic systems and its involving the animation of cylinders user can identify and
components for easy access to the marked segments of the arrangement of rollers system for color and wetting,
application. The application has the capabilities for users cylinder arrangement and movement of sheet on which is
to test themselves. printed.
The user moves around through the application virtual
rooms (printing office or laboratories), which reinforces
the sense of belonging, or presence, and thus increases the
involvement, motivation and participation in learning.
The user can call a graphical interface at any time to
quickly access desired content, without the need to move
around the virtual environment. The concept of interactive
applications is presented in Figure 2.
Fig.4. KBA Rapida 75 machine for offset printing
Fig.2. The concept of applications interactive Fig.5. 3D model mash of a system of cylinders
laboratories
Complete information of all printing units gets to render a
5.2. Digital printing machines model that gives an overall information of the structure
and process of the machine (Figure 6).
When choosing a particular graphic system either through
a virtual environment or a graphical interface, the user can
focus on the review of the certain graphic system. Figure
3 shows an example of a 3D visualization of digital
printing machine with access to information on individual
segments of the system.
Fig. 6. Structural and process view of machine
Figure 7 presents the structure of the transmission system

for sheet delivery system.
Fig.3. Visualization of Riso EZ570 Digital Printing

System
5.3. Offset printing machines
Offset printing technique includes over 80% of the market
so that printing offset printing machines take especially
significant place in graphic production processes. In
addition to getting acquainted with the appearance of
graphic systems for offset printing (Figure 4), greater
interest is the examination of the internal structure
elements with which graphic system works. Figure 5
shows the mesh of the 3D model of the system of
cylinders within the machine KBA Rapida 75. The mesh
is due to the generation of 3D models in 3D max, Fig.7. Sheet delivery system
91
5.4. Postpress machines development of multimedia content for the purposes of

the e-learning platform about graphic systems would be
In the case of postpress machines (Figure 8) the user of
based on a detailed visualization of setting graphic
the application can see the operation of folding graphical
systems, with the present requirements for setting
materials, where the developed application can show
machine on the ground, simulation of possible errors
moving and folding sheets in slow motion.
during the folding process and visualization software of
digital machines with the possibility of creating tasks as
jobs for which future operator will adjust the parameters
for printing.
ACKNOWLEDGEMENTS
This research was supported by the Serbian Ministry of

Science and Technological Development, Grant
No.:35027 "The development of software model for
improvement of knowledge and production in graphic arts
industry"
Fig.8. Folding machine Horizon AFC-544AKT

REFERENCES
6. DISCUSSION
In order to improve the educational process in the printing [1] Punik, M.; umak, B. & Heriko, M., (2010).
industry, a platform for distance learning in the virtual Investigation of Virtual Learning Environment in The
environment has been developed. The platform is Context of Web 2.0. Second International Conference
adaptable in terms of selecting a large number of on Mobile, Hybrid, and On-Line Learning
machines in the virtual space and depending on the [2] Rosenberg, M. (2001). E-learning: Strategies for
machine about you want to study. The paper presents the Delivering Knowledge in the Digital Age, The
segments of developed platform for distance learning in McGraw-Hill Companies, Inc., ISBN 0-07-136268-1,
the field of graphic machines in different printing United States of America
techniques including the main capabilities of user- [3] Popovi, N. & Naumovi, M, (2009). Realizacija
machine interaction elektronskog kursa iz upravljakih sistema u Moodle
okruenju, Vol. 8, pp. 511-515, Infoteh, Jahorina
7. CONCLUSION [4] Fernandes, J. (2009). Moodle 1.9 Multimedia, Packt
Publishing Ltd., ISBN 978-1-847195-90-6,
The virtual environment attracts the interest of users of Birmingham
the application; a conventional graphical user interface [5] Mahbubur R., (2009). Methods and Applications for
leaves the possibility for simplified application Advancing Distance Education Technologies:
management. Multimedia applications integrated into the International Issues and Solutions, Information
learning platform Moodle increase the quality of learning Science Reference, ISBN 978-1-60566-342-5,
about graphic systems. Further research in terms of the Mankato, USA
92
Research paper
VIBRATION MONITORING SYSTEM BASED ON PIC MICROCONTROLLER

Ljubomir VRAAR1, * - Milo MILOVANEVI2 - Petra KARANIKI3
1 University of Nis, Faculty of Mechanical Electronic, Nis, Serbia
2 University of Nis, Faculty of Mechanical Engineering, Nis, Serbia
3 University of Rijeka, Head of Technology transfer office, Rijeka, Croatia
Abstract: The purpose of the research presented in this paper is the development of the optimal micro configuration for
vibration monitoring of pumping aggregate, based on Microchips microcontroller (MC). Hardware which is used is
the 10-bit MC, upgraded with 12/bit A/D converter. Software for acquisition and data analysis is optimized for testing
turbo pumps. The authors have performed numerous measurements on wide range of turbo aggregates in order to
establish the operating condition of pumping aggregates.
Key words: micro configuration, vibration monitoring, microcontrollers
1. INTRODUCTION the quality of vibration monitoring in general. Selection

of the microcontroller that is a base for micro system has
The development of non-invasive methods of monitoring been done primarily considering economical aspects of
enabled the transition from preventive to predictable newly developed system which is PC (personal computer)
maintenance. There are various indicators for machine dependant [2]. Microchip, a company that is producing
condition (temperature, pressure); however, the method microcontrollers for more then a decade, as well as
of use vibration monitoring for determination of machine microcontroller PIC16F877A, that has been developed as
operating conditions was proved the best. Monitoring symbioses of microprocessor (CPU), memory and
system based on MC is developed because vibrations- periphery, there for PIC is acronym for (Peripheral
based monitoring is used in large number of cases for Interface Controller) [3]. This microcontroller is based on
determining machine condition. This system is created to CMOS technology with RISC architecture and
meet certain demands: monitoring platform based on use implemented FLASH and EEPROM memories. Thus,
of common PC, low cost of the device, mobility, 12-bit PIC16F877A represents the best compromise between
resolution and application on rotational machines. price and technology. Main signal characteristics that
have been chosen as main requirements for the design of
2. USE OF MC IN MONITORING an optimal micro system are: resolution, stability and
repeatability of signal. In order to fulfill requirement of
resolution an A/D converter is added, since
Microcontrollers (MC) are electronic components
microcontroller has 10-bit resolution, a MCP3204 12-bit
designed to develop electronic systems for digital
A/D converter is connected via SPI connection protocol
command and control. With the use of such systems it is
[4].
possible to control several electronic devices and systems,
to collect and process various electric and non-electric 3. SIGNAL REPEATABILITY TESTING
quantities. Digital systems based on microcontrollers are
programmed to perform distinct processing depending on Analyses of main, selected signal characteristics have
condition of control circuit, and to assume command in significant influents in optimal micro system selection.
circuit by using gained results of this processing. Significant signal resolution has been obtained by
There is a very wide range for microcontroller usage, introducing MCP3204 12-bit A/D converter and stability
because they can be programmed, depending on the is insured by selecting the leading electronic components
desired usage, to obtain the type of behavior of the digital manufacturers and implementing their components. Thus,
device we design [1]. testing signal repeatability in laboratory conditions, on
With the intention to analyze of pumping aggregate signal generators Tektronix 3102 and Tektronix dpo 4034,
operating condition, the authors of this paper had is a method for selecting an optimal micro configuration.
designed a special MC developing environment, with its The following diagrams represent a part of intensive
description given in a shortened form. signal repeatability testing of selected optimal micro
2.1. Functional requirement of micro system for configuration.
Signal repeatability has been tested by two types of
vibration monitoring
complex signals: exponential and triangle. Exponential
Considering micro systems for vibration monitoring, the signal in repeatability testing is presented in Figure 1 in
signal characteristics determine the system accuracy and the following order, a) original signal screen shot of a
*Correspondence Authors Address: University of Nis, Faculty of Mechanical Electronic, Aleksandra Medvedeva 14, 18000 Nis,
Serbia, ljubomir.vracar@elfak.ni.ac.rs
Ljubomir Vraar, Milo Milovanevi, Perta Karaniki: Vibration Monitoring System Based on PIC Microcontroller;
referent testing signal, b) fast furrier transformation (FFT) recognition of critical operating conditions. Operation of
diagram of collected signal from tested configuration, c) centrifugal pumps is accompanied by two undesirable
collected signal from tested configuration without side effects: vibrations and noise. The intensity level of
transformation. vibrations and noise characterize the perfection of pump
Triangle signal in repeatability testing is presented in operation, its construction and pump condition during
Figure 2 in the following order, a) original signal screen exploitation period, as well as cavitation phenomenon in
shot of referent testing signal, b) fast furrier the pump. More about all these effects to the emitted
transformation (FFT) diagram of collected signal from noise as a side effect of centrifugal pumps is given in [5,
tested configuration, c) collected signal from tested 6].
configuration without transformation. This testing has The sources of vibrations in centrifugal pumps are
proved that selected optimal micro configuration for mechanical, hydraulic and electrical processes caused by
vibration monitoring based on microcontroller has a the pump construction, operating regime, exploitation and
suitable performance regarding signal characteristics. manufacturing technologies used. Due to the blade
passage frequency (BPF) with frequency
f z z / 2 zn , where z is the number of impeller
blades and n is the rotational speed in rps. Disbalance of
rotational masses of rotor is caused by oscillation with

frequency f1 .
2
Fig.1. Diagrams of signal repeatability testing by

exponential signal
4. IDENTIFICATION OF PUMPING
AGGREGATE VIBRATION PARAMETERS
It is necessary to take safety measures to assure the Fig.2. Diagrams of signal repeatability testing by triangle
precision of turbo pumps operating conditions. It is signal
considered that a basis of supervision is the control of
vibrations and their measuring via electric means. The Vibrations caused by the collisions of parts in the contact
primary objective of all safety measures is timely are produced in bearings, gear box, couplings and
94
connected shafts of the pump and the driver. Rolling 4.2 Result analysis of pump aggregate measuring
bearings may produce vibration with frequency often
Measuring result analysis is generated using the
lower than 30 kHz.
frequency spectra. Presented diagrams are created from
Disturbance force is generated by connecting a pump and
FFT algorithm, adapted for pump aggregate diagnostics.
a driver shaft with the geared coupling, with the
Measuring point 1, Fig 4. a), horizontal and vertical

frequency f 2 z s , (zs- number of coupling teeth). acceleration not exceeding the 1 m/s can be observed,
2 indicating the proper operating condition of the electro
Electromotor vibrations are caused by disturbance forces motor (EM) bearing. There are also no vibrations in a
generated from variations of electromagnetic field, with frequency range 700-900Hz which is an indicator that the
motor fan is correctly installed.
frequency for this case: f E z w , (zw- number of
2
motor poles).
Mechanical vibrations of pumps were the subject of
numerous researches. Result analysis draws the
conclusion that the level of vibration can be lowered with
respect to the certain instructions and recommendations in
balancing of rotational masses, selection of bearings,
couplings, eccentricity between the shaft axis of pump
and driver, etc.
Hydrostatic vibrations of centrifugal pumps are the result
of vortex arisen in liquid stream, flow heterogeneousness,
turbulent pulsation of speed and pressure, and cavitations
phenomenon [5, 6]. Intensity of vibrations, caused by
vortex sources, is proportional to the sixth grade of stream
line peripheral speed. Various measurements were
performed at pumping aggregates with centrifugal pumps
for water supply in municipality of Nis and its
surroundings. Two types of pumps were tested:
multistage horizontal and well pumps, using the MC
device described in chapter (2) of this paper.
4.1 Vibration monitoring at centrifugal pumps
Horizontal pumps have a significant role in water
transportation. This role of horizontal pumps defines also
the importance of providing the flawless work. Electro
motors of horizontal pumps are extremely burdened from
the aspect of continuous exploitation for maintaining the
permanent operation. Adequate choice of measuring point
at a pump aggregate of a horizontal pump can indicate the
operating condition for electromotor bearings and rotor,
the pumping aggregate bearings and coupling, and
complete aggregate construction likewise Fig.3.
The following measuring points are chosen:
The first measuring point is chosen for the operational
condition diagnosis of the first bearing at
electromotor.
The second measuring point is defined to diagnose the
condition of driving electromotor second bearing
The third measuring point is determined in such a
manner that it is possible to diagnose both the
condition of pump first bearing and elastic coupling.
The fourth measuring point is defined to diagnose the
condition of pump second bearing.
Fig.4. FFT diagrams for horizontal pump aggregate

Fig.3. Measuring point at horizontal pump aggregate CVNR 5-3, No.1 at measuring points (MP), a) MP 1, b)
CVNR 5-3, No.1 MP 2, c) MP 3, d) MP 4.
95
Measuring point 2, Fig 4. b), high acceleration amplitude new generation of microcontrollers. In the diagnosis of
at frequency at 310Hz is a manifestation of incorrect pumping aggregate malfunctions, frequency spectrums
coupling working condition, the second electro motor have a crucial role in defining the causes of failure.
bearing is in a good operating condition. Created monitoring system has significant results in
Measuring point 3, Fig 4. c), based on the acceleration frequency vibration analyses regarding mechanical
there can be seen the precise bearing operation, and based defects detection of the pumping aggregate.
on the analyses of the previous diagrams, incorrect
coupling operating condition.
Measuring point 4, Fig 4. d), it can be concluded that the REFERENCES
operating condition of the second bearing of the pump is
satisfactory. [1] MATI N., D. Andri, 2000 PIC mikrokontroleri,
In order to comprehend the results previously presented, it Mikroelektronika Beograd.
is necessary to emphasize that the frequency amplitude [2] MILOVANEVI, M., CVETKOVI M.:
diagrams are the result of a specially created FFT Application of new microcontroller generation for
algorithm. The result of several years of research and pump aggregate working condition analyses, Journal
development of vibration monitoring in order to Research and Desing in Commerce & Industry.
determine the operating condition for most of the pump ISSN 1451- 4117 UDC 33. Br.23/24. 2009. p.p. 35-
aggregates used in industry is presented in Fig 4. The 41, Belgrade 2009
diagram presented in Figure 4 (a, b) points to the [3] MILOVANEVI, M., CVETKOVI M.:
following facts: in electro motor, it is possible to Applicative approach to vibro-diagnostic model
determine a bearing malfunction as well as other optimization for turbo pumps, Journal Research and
mechanical defects such as incorrect coupling operating Design in Commerce & Industry. ISSN 1451- 4117
condition. UDC 33. Br.25. 2009. p.p. 41-48, Belgrade 2009.
The diagram presented in Figure 4 (c, d) presents pump [4] MILOVANEVI M., VEG A.: Application of
bearing malfunction but also a high frequency range, axiomatic design on vibro-diagnostic system 9th
which is appearing as a result of hydro-dynamic processes International Conference Research And
in a pump. Development In Mechanical Industry RaDMI, p.p.
The presented data is a small segment of the research; 295-301, Serbia 2009.
over 230 pump aggregates were analyzed in order to [5] UDINA, M. Detection of cavitation phenomenon in
improve the mathematical apparatus and software for a centrifugal pump using audible sound. Mechanical
vibration analysis. In the table, there are the absolute System and Signal Processing, 2003, Vol. 17, No. 6,
values of acceleration; bold values are marked as pp. 1335-1347.
analyzed in the previous diagrams; the table is a part of [6] UDINA, M., PREZELJ, J. Use of audible sound for
the project report and the starting point is in the analysis safe operation of kinetic pumps. International Journal
of operating condition. of Mechanical Science. 2008, Vol 50, No. 9, pp.
1335-1343.
5. CONCLUSION
Examination of pumps vibration phenomenon provides

the data about the vibration magnitude and its frequency
components as well as their change with respect to the
operating parameters. On the basis of obtained results, the
safety level for pump and the whole plant is evaluated.
Beside mentioned, in most cases it is necessary to
determine the cause of non-stationary occurrences.
Operating ranges that should be avoided are determined in
many cases. Primary sources of vibrations at centrifugal
pumps are mechanical, hydraulic and electric processes
caused by the design of a pump, its manufacturing
technology, operating regime and exploitation condition.
It is possible to eliminate the mechanical and electrical
sources, partially or completely, lowering the vibrations
level in that way.
However, hydraulic vibrations are hard or almost
impossible to avoid. Hydraulic processes which happen in
pumps are complex and non-stationary by the rule. For
description of such processes it is possible to form
mathematical models, whose evaluation is performed
after very comprehensive, expensive and long-lasting
researches.
For these reasons such models were not considered in this
paper here are the experimental results obtained by
newly developed vibrodiagnostics device, based on the
96
Research paper
APPLICABLE IMPORTANCE OF VIBRO-DIAGNOSTICS IN PREDICTABLE

MAINTENANCE OF NAISUS AQUEDUCT SYSTEM
Milo MILOVANEVI1, * - Ljubomir VRAAR1 Sanjin TROHA2

1 University of Nis, Faculty of Mechanical Engineering, Nis, Serbia
2 University of Rijeka, Faculty of Engineering, Rijeka, Croatia
Abstract: In order to secure the working order of mechanical systems, it is necessary to ensure a variety of supervision
measures of working reliability. Basis of this control are supervision of vibrations and their measuring by electric
devices. Naissus waterworks with its wells, intake system, adequate distribution and manifold network, pumping
stations and water reservoirs all represents the Nish Aqueduct System (NIVOS). It supplies with fresh water about
240,000 people and very diverse industry of Nish municipality with 103,377 cubic meters per day, making it 37,732,608
cubic meters per year. Important part of this complex system of water distribution to consumers is about fifty functional
pumping stations. These pumping stations contain 115 pumping power units with different assignments. Use of
vibrodiagnostics to provide predictable maintenance is a key segment in realization of the flawless work for pumping
power units [1, 3, 5, 7].
Key words: water distribution, vibrodiagnostics, pumping power units
1. INTRODUCTION
Mentioned systems with its wells, intake systems,
Water distribution of Nish municipality today is achieved belonging distribution and manifold network, pumping
via three territorially separated, but functionally very stations and water reservoirs all represents the Nish
dependable waterworks systems. These are:
Aqueduct System (NIVOS), Fig. 1. It supplies with fresh
Waterworks system MEDIANA ground water water about 240,000 people and very diverse industry of
well supplemented with previously purified water Nish municipality with 103,377 cubic meters per day,
from Nishava River, capacity 100 to 150 liters per making it 37,732,608 cubic meters per year.
second.
Waterworks system STUDENA natural well and
intake piping with facilities, capacity 220 to 340 liters 2. JKP NAISSUS NISH PUMPING
per second.
STATIONS
Waterworks system LJUBERADA-NISH group
of natural wells (Krupac, Mokra, Divljana and
Important part of this complex system of water
Ljuberada) and intake piping with facilities, capacity
800 to 1,450 liters per second. distribution to consumers is about fifty functional
pumping stations. These pumping stations contain 115
pumping power units with different assignments. Use of
vibrodiagnostics to provide predictable maintenance is a
key segment in realization of the flawless work for
pumping power units. The most convenient procedure in
this case, to secure flawless work of the system, is
vibrodiagnostics [2, 4, 6, 8].
Measurings were performed at Knez selo pumping
station to determine its working capabilities Fig. 2.
Knez selo pumping station main function is to increase
water pressure and fill the reservoir. Its pumping power
units operation is periodical. Pump designation is VP 50-5
with 4.4 to 9 liter per second flow; its electromotor
Fig.1. Nish waterworks system operates at 2910 rpm, Fig. 3.
*Correspondence Authors Address: University of Nis, Faculty of Mechanical Engineering, Aleksandra Medvedeva 14, 18000 Nis,
Serbia, milovancevic@masfak.ni.ac.rs
Milo Milovanevi, Ljubomir Vraar, Sanjin Thora: Applicable Importance of Vibro-Diagnostics in Predictable Maintenance
of Naisus Aqueduct System; Machine Design, Vol.7(2015) No.3, ISSN 1821-1259; pp. 97-100
Fig.2. Vibrodiagnostics system on pumping power unit
that maximal value of vertical acceleration is 3 meters per

square second Fig. 4a and 4b. The maximal value of
vertical acceleration at other two point 1,5 meters per
square second.
One-dimensional discreet FFT analysis, which was used
to transform the vibration spectrum from time to frequent
domain, provide the actual condition of bearing working
order. The analysis of frequency-amplitude diagram
shows that bearing is not in order, i.e. there is damage
either bearing sleeve or its rotation units Fig. 5a and 5b.
Measuring of vertical and horizontal vibrations on pump
bearing cover indicate that there is no damage on bearing.
Also clearly noticeable are amplitudes from frequency
spectrum, which depicts the vibration transition from
engine rotor shaft and over clutch, all the way to pump
shaft Fig. 6a and 6b.
Fig.3. Pumping power unit 3 m/s2
3. MEASURING POINTS SELECTION
Correct selection of measuring points is a key factor in

working order diagnostics, especially if vibro-diagnostics
2 m/s2
procedure is applied. For use of vibro-diagnostics
procedure at Knez selo pumping station, the measuring
points were defined to diagnose working order of bearings
on pump shafts and the electromotor shafts.
Measuring points are the following ones:

1. Measuring of electromotor bearing vibrations 1 m/s2
2. Measuring of pump bearing vibrations
3. Measuring of pump bearing vibrations
Hz
3.1. Performed measurings
First measuring point is located at rotor bearing cover.
Choice of this measuring point enables diagnose of
bearing absolute vibrations. Measuring results indicates Fig.4a. Measuring at first point
98
4. CONCLUSION
Vibro-diagnostics represents a significant tool in

determining the mechanical systems working order. The
use of frequency-amplitude analysis in determination of
pump power units working order condition is a quick and
simple way to bearing diagnose based on absolute
vibrations. Special importance and great specific
magnitude have measuring that via determining the
system working capability prevents damage halts.
Diagnostics of pumping systems for waterworks is
important from the aspect of maintaining the production
process continuity. In the implementation of FFT
analyses, significant influence of the pump blades at
Fig. 4b. Measuring at first point amplitude-frequency diagram can be established.
Vibration transition from engine rotor shaft to coupling
1.5 m/s2 with pump shaft is easily observed as well.
Diagnostics of pumping power units based on FFT
analysis of vibration spectrum of pump engine work
proved itself in this case very successful. Measuring
results clearly indicates flaws at pumping power unit
1.0 m/s2 engines. Overviewing all previously mentioned, the
conclusion can be drawn that vibro-diagnostics of
pumping power units engine working order is potent
weapon in struggle with damage failures [10, 11]
0.5 m/s2
Hz
0 50 100 150 200 250 300 350 400 450 50 REFERENCES
Fig.5a. Measuring at second point [1] Mati N., Andri D., 2000, PIC mikrokontroleri,
Mikroelektronika Beograd.
[2] Milovanevi, M., Cvetkovi M., 2009, Application
of new microcontroller generation for pump
aggregate working condition analyses, Journal
Research and Desing in Commerce & Industry, p.p.
35-41, Belgrade.
[3] Milovanevi, M., Cvetkovi M., 2009, Applicative
approach to vibro-diagnostic model optimization for
turbo pumps, Journal Research and Desing in
Commerce & Industry, p.p. 41-48, Belgrade.
[4] Milovanevi M., Veg A.,2009, Application of
axiomatic design on vibro-diagnostic system, 9th
International Conference Research And
Development In Mechanical Industry RaDMI, p.p.
295-301, Serbia.
[5] udina, M. , 2003, Detection of cavitation
Fig.5b. Measuring at second point phenomenon in a centrifugal pump using audible
sound, Mechanical System and Signal Processing,
Frequency picture, obtained by measuring at pump Vol. 17, No. 6, pp. 1335-1347.
[6] udina, M., Prezelj, J., 2008, Use of audible sound
bearing cover, indicates that there is significant influence
for safe operation of kinetic pumps, International
of pump impeller at amplitude-frequency diagram Journal of Mechanical Science. Vol 50, No. 9, pp.
(segment 2 from Fig. 6a). 1335-1343.
99
[7] udina, M., Prezelj, J., 2009, Detection of cavitation [9] Grjanko L. P., Papir A N., 1975, Lopastine nososi,
in operation of kinetic pumps, use of discrete Mainostroine Leningrad.
frequency tone in audible spectra. Applied [10] Milenkovi D., 1988, Nestabilno strujanje kroz kola
Acoustics. Vol. 70, No. 4, pp. 540-546. turbomaina izazvano globalnim gubitkom
[8] Milovanevi M., Stefanovi Marinovi J., stabilnosti, 18. jugoslovenski kongres teorijske i
Anelkovi B. Veg A., 2010, Embedded condition primenjene mehanike, Vrnjaka Banja, str. 320-326.
monitoring of power transmission of a pellet mill. [11] GOST 1373168 (State all union standard),
Transactions of Famena XXXIIII-2 (2010), Faculty Mechanical vibration, vibration characteristics
of mechanical engineering and naval architecture, control 12.1.003-76.
pp. 71-79, Zagreb
100
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2 University of Miskolc, Faculty of Mechanical Engineering, Miskolc, Hungary
3 Silesian University of Technology, Dept. of Engineering Processes Automation and Integrated Manuf. Systems, Gliwice, Poland
Received (xx.xx.20xx); Revised (xx.xx.20xx); Accepted (xx.xx.20xx)
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clearly displayed by leaving single line of spacing above [1] Spotts, J.; Blitzer, W. & Gingrich, T. (2007). Name of
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[7] *** (2005) TFOD machine & transmission trends
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UNIVERSITY OF NOVI SAD

FACULTY OF TECHNICAL SCIENCES

novi sad, 2015

technical preparation and cover design

Electronic version of journal available on

machine design is covered by the following indexes

DOAJ Directory of Open Access Journals

MACHINE Design / editor in chief Sinia Kuzmanovi. - 2009- .- Novi Sad :

Prof. Ph.D. Sinia Kuzmanovi

3. Construction Solution and Estimate of Important Elements Assemblies of Log Splitter

4. End-Milling Force Control System With Surface Roughness Monitoring

5. Application Development for Learning About Graphic Systems Integrated

6. Vibration Monitoring System Based on PIC Microcontroller

7. Applicable Importance of Vibro-Diagnostics in Predictable Maintenance of Naisus

IMPACT ANALYSIS HEATING PLANTS TO THE ENVIRONMENT AS AN INITIAL STEP IN

Received (20.05.2015); Revised (08.06.2015); Accepted (11.06.2015)

Key words: emissions, cogeneration, energy consumption

1. INTRODUCTION cogeneration plants (III 42013) "This project is under the

Table 2. Consumption of fuel for heat production

Year Coal [t] Crude oil [t]

Table 3. Fuel consumption for heat production

Data listed plants ie. data boilers (number of boilers,

Table 4. Annual emissions in the production of thermal

2009/10 2008/09 2007/08 The amount of

Table 5. Annual emissions in the production of thermal

Table 9. Projected final energy consumption by 2020, the 20000

OBTAINNIG THE MAXIMUM LOAD OF THE BENDING LOAD ELEMENT CONSIDERING

Received (15.05.2015); Revised (08.06.2015); Accepted (11.06.2015)

Key words: reliability, bending loaded element

1. INTRODUCTION where A and B are random variables where: A is the

Fig.3. Highlighted area of standard deviation

Highlighted area on the drawing (Fig.2) represent that the

Where f A, B is density of the distribution of the random

From the previous expression reliability D is determined

To determine the value of the force P = ? Which for the

Where: is the average value of the resistance, in this

Than we have: Table 1. Variation of the force, reliability, expression

[1] .., ..,

This paper has shown mathematical model to take into

CONSTRUCTION SOLUTION AND ESTIMATE OF IMPORTANT ELEMENTS

Received (18.05.2015); Revised (08.06.2015); Accepted (11.06.2015)

Key words: construction solution, wood splitter, estimate

2. CONSTRUCTION SOLUTION OF WOOD

applying the methods of modern product development a

Fig.2. Conceptual sheme of the splitter

2.1. Functional analysis of subassemblies

Bracket for central lever of tractor is multifunctional and

Fig.7. Holder for hand

Fig.6. Reservoir with fuel cap

Handle is made from standard tubular profiles and

On the basis of the calculations adopted by the hydraulic

Fig.10. Scheme of the cylinder

The oil flow through the system

Based on the speed of the bladev, required oil

Q Minimum value of hose diameter is calculated from

Choice of hydraulic oils

The safety valve is set at the maximum pressure value and

pMAX 180 bar .

Valve for pressure relief is adjusted in the starting

prelieve 58.25 bar .

Calculation for hydraulic hoses in the system

Start viscosity of the oil: 46 mm