The aim of research and development work and experimental work carried out at Tomasz Dudziak Metalworking was focused on the development and implementation of innovative technology for the production of wheels leading to machines producing optical fibers, enabling the production of long-length beams. The key assumption of the project was to increase precision and eliminate manufacturing defects resulting from external factors, such as ambient temperature or centrifugal force affecting the production process. An important goal was also to reduce production waste and increase the efficiency of the process. Research and development included the improvement of machining techniques and tooling modification, including the use of modern tool coatings and the improvement of machine operating conditions by stabilizing the temperature at the production site. Various technological variants were tested to achieve a higher quality of the final product, including improved repeatability and dimensional accuracy of products. As part of the research and development work, the impact of operating conditions on the quality of production and durability of wheels was carefully analyzed. The conducted tests included measurements of vibrations, analysis of wheel beating and assessment of their strength in changing temperature conditions. The research assumes that: 1. reducing the amount of production waste will be possible by optimizing the machining process and eliminating external factors that negatively affect the quality of products, 2. increasing the precision of the rotation of guide wheels will be achieved through the use of modern tool coatings and improved handles eliminating the impact of centrifugal force, 3. acceleration of the production process will occur as a result of the introduction of new machining technologies and the use of CNC lathes with greater efficiency, 4. limiting the operator's influence on the final production effect will be realized through the use of automatic measuring systems, which will allow to maintain repeatability and stability of production parameters. As part of research and development, various design and technological variants were tested. Material modifications have been introduced, such as the use of 7075 aluminum, which ensures appropriate lightness and mechanical strength, which allows stable and precise operation of the wheels at high rotational speeds. An important element of the project was also the development of advanced lathe tooling, which eliminates vibrations and deformations during the processing of elements, which significantly improves the quality of wheels. Thanks to the use of automatic measurement systems and modern machining methods, very high precision has been achieved, minimizing axial and radial deviations. The introduction of an anode coating with a thickness of 20 microns further increased the durability of the wheels, protecting them from wear and adverse external factors. One of the most important results of research and development was the development of an optimal design of the guide wheel, made of 7075 aluminum, characterized by high aesthetics and mechanical resistance. The project aims not only to increase the production efficiency of optical fibers, but also to reduce costs by reducing the number of defective products and reducing material losses. The developed technology provides a solid basis for further deployment on a larger scale and can bring significant benefits to the fibre manufacturing industry not only domestically but also internationally. As a result of the work carried out, the guide wheels are characterized by much better stability, precision and durability compared to previous solutions, which allows for more efficient and safe production of fiber optic fibers. The details of the research and development work are presented in the attached report on the research and development work carried out at Tomasz Dudziak’s company.
