This paper presents the study of the impact of vibration induced by the movement of the railway rolling stock on the Forum Gdańsk structure. This object is currently under construction and is located over the railway tracks in the vicinity of the Gdańsk Główny and Gdańsk Śródmieście railway stations. The analysis covers the influence of vibrations on the structure itself and on the people within. The in situ measurements on existing parts of the structure allow us to determine environmental excitations used for validation and verification of the derived FEM model. The numerical calculations made the estimates of the vibration amplitudes propagating throughout the whole structure possible.

Numerical analysis of the tensioning cables anchorage zone of a bridge superstructure is presented in this paper. It aims to identify why severe concrete cracking occurs during the tensioning process in the vicinity of anchor heads. In order to simulate the tensioning, among others, a so-called local numerical model of a section of the bridge superstructure was created in the Abaqus Finite Element Method (FEM) environment. The model contains all the important elements of the analyzed section of the concrete bridge superstructure, namely concrete, reinforcement and the anchoring system. FEM analyses are performed with the inclusion of both material and geometric nonlinearities. Concrete Damage Plasticity (CDP) constitutive relation from Abaqus is used to describe nonlinear concrete behaviour, which enables analysis of concrete damage and crack propagation. These numerical FEM results are then compared with actual crack patterns, which have been spotted and inventoried at the bridge construction site.

This article deals with the problem of determining the resistance of end-plate connections. A nonlinear FEM model of the joint was constructed in order to predict its carrying capacity. A standard code procedure was done as well. The analyses have been done to assess atypical end-plate joints designed and constructed as a part of roof structures.

The article reports the results of a comparative analysis made for three novel unconventional gear wheel forging processes based on the authors’ patented [5,6,21] plastic forming methods developed chiefly for the purposes of extruding hollow products as well as valves and pins. These processes are distinguished by the fact that part of the tooling elements which are normally fixed during conventional forging are purposefully set in motion. This is intended to change the conditions of friction at the metal-tool contact surface and to induce additional thermal effects due to the transformation of the plastic deformation energy into thermal energy and, as a consequence, to improve the plastic flow of metal and to reduce the force parameters of the process.

The article proposes the implementation of a novel method of plastic forming of internal toothing in flange spline sleeves. A method being the subject of Polish patent application P.416772 has been used for this purpose, which involves a combination of the scheme of the direct extrusion of a cone hollow with the die press forming of the wall to obtain a flange. The entire process takes place in a single technological sequence. The operations come one after another, so that there is no need for reheating the stock or carrying out intermediate soft annealing. The proposed method is assumed to be an alternative to the operation of press forming of internal spline sleeve toothing in a conical die [1] and to the operation of swaging on rotary swaging machines [2]. It is assumed that this method, too, is alternative to other technologies known from the literature and industrial practice, whose specifications and literature references will be indicated later on in this paper. Computer simulations of the flanged sleeve plastic forming process were performed using the commercial numerical program Forge®3D. During the numerical computations, the distributions of temperature fields were determined on the cross-section of the plastically formed product. The computations enabled also the visualization of the plastic flow of metal, especially in the toothing forming regions, and the determination of the energy and force parameters of the process.

Residual stress has a great influence on the metal, but it is difficult to measure at small area using a general method. Residual stress calculations using the Vickers indentation can solve this problem. In this paper, a numerical simulation has been made for the residual stress measurement method of metal material deformed by high-speed impact. Then, the stress-strain curve at the high-speed deformation was confirmed through actual experiments, and the residual stresses generated thereafter were calculated by the Vickers indenter method. A Vickers indentation analysis under the same conditions was performed at the position where a residual stress of about 169.39 MPa was generated. Experiments were carried out and high speed impact was applied to the specimen to generate residual stress. The obtained results indicate that it is possible to identify residual stresses in various metals with various shapes through Vickers indentation measurements, and to use them for process and quality control.

The publication presents a novel concept of the process of plastic forming of variable longitudinal-section cylindrical products, being the subject of Patent Application P.427426 [1]. Additionally, these products are provided with a connection stub pipe. The plastic forming method proposed in the article combines many advantages and utilitarian benefits associated with the manufacturing technology itself, as well as with its further implementation. Using stock in the form of normalized bar commonly available in the metal product market as a finished product obviously reduces the process costs involved with stock preparation, i.e. casting, rolling, machining, etc. It also results in obtaining a much smaller surface area of stock contact with the tool and, as a consequence, a smaller surface of stock friction against the tool, which contributes to a reduction of force needed for the plastic forming of the product. The smaller contact surface area and the shorter time of stock contact with the cooler tool cause, above all, less intensive heat exchange and stock chilling. This has a significant effect on the plasticity of the cast material and, as a consequence, the plastic forming force. The proposed method enables also manufacturing cylinders with either a closed or open stub pipe with a regulated length and a varying section. In addition, unlike the method known from Polish Patent Specification PL 212062 [2], the proposed method does not require using a multi-tool press. The upper punch is furnished with a flange, whose job is to start the stock extruding sleeve at the next process stage.

The paper presents selected simulation and experimental results of a hybrid ECPMS-machine (Electric Controlled Permanent Magnet Synchronous Machine). This permanent magnets (PMs) excited machine offers an extended magnetic field control capability which makes it suitable for battery electric vehicle (BEV) drives. Rotor, stator and the additional direct current control coil of the machine are analyzed in detail. The control system and strategy, the diagram of power supply system and an equivalent circuit model of the ECPMS-machine are presented. Influence of the additional excitation on the performance parameters of the machine, such as: torque, efficiency, speed limits and back-EMF have also been discussed.

Pavements made of cement concrete, used for road constructions, are damaged during use. This applies to both the pavements of rural and forest roads with very low traffic loads, as well as road pavements with high traffic loads. One of the most effective ways of repairing damaged concrete cement pavements is through placing an asphalt overlay on a concrete slab. In order to increase the fatigue life of the asphalt overlay, asphalt mixtures are modified with fibres. One technological solution is to use FRP (Fiber Reinforced Polymer), an innovative material with improved properties.

The aim of this paper is to assess the impact of asphalt overlays modified with a new type of fibres to strengthen the durability of weakened cement concrete pavement structures.

On the basis of the conducted analyses, it was shown that the use of an asphalt layer reinforcement increases fatigue life, for both 15 cm thick prefabricated slabs and a typical road pavement for average traffic made of 25 cm doweled and anchored concrete slabs. There was a significant increase in the fatigue life of the concrete pavement structure as a result of modifying the overlaid asphalt mixture with FRP fibres.

The problem of effective gas extraction from Polish shale rocks is an interesting research subject for scientists. A properly selected proppant, which protects cracks from closing during the fracturing process, inestimably contributes to an increase of extraction. Grains of proppant are transported along with a fracturing medium to reach the deepest regions of the crack. The proper support of the crack provides an easy flow of gas, therefore it is important in terms of extraction efficiency. This paper shows the interactions of a proppant grain with the crack surface in shale rock. FEM analysis was conducted to observe the stress region, which is generated as a result of pressing the grain into the crack surface. A model of a sphere which was pressed into the rock model with constant velocity was applied. The received results of stress depend on material properties and a range of proppant grain pressing.