Martin Mantič

This paper presents a numerical case study on the application of generative design to the shape optimisation of a spur gear body with consideration of manufacturing constraints and material properties. The presented results are obtained using numerical simulation and finite element analysis. A finite element-based generative design workflow was employed to evaluate weight reduction and stiffness performance under different manufacturing routes, including additive manufacturing, machining, and casting. The results show that the application of generative design enabled a gear-body mass reduction of up to 37.46–45.68% compared to the reference geometry while maintaining acceptable deformation levels. Designs constrained for additive manufacturing achieved the highest weight savings, whereas machining-constrained variants exhibited lower deformation values, indicating higher structural stiffness. Casting-oriented constraints resulted in more conservative geometries with locally reinforced regions. The study confirms that manufacturing constraints significantly influence the generated geometry and mechanical response, demonstrating that the manufacturing route acts as an independent design variable within the generative design process. The presented methodology provides practical guidance for the early-stage numerical optimisation of gear bodies and supports informed decision-making with respect to manufacturing technology selection.

This work investigates the application of generative design in the development of gear wheels, with emphasis on the relationship between geometry, manufacturing technology, and material selection. Material properties such as strength, stiffness, fatigue resistance, and manufacturability significantly influence both the achievable level of shape optimization and the resulting weight reduction. Generative design enables the adaptation of gear-body geometry to the mechanical characteristics of individual material classes, supporting efficient material utilization while ensuring the required stiffness. The study evaluates the effects of various manufacturing technologies—additive manufacturing, subtractive machining, and casting—by considering material processability and structural constraints. The results demonstrate that the combination of material and manufacturing method substantially shapes the design space: additive manufacturing allows lightweight and organic structures with high geometric freedom; milling requires tool-accessible geometries; and casting benefits from local reinforcement in the area around lightening holes, improving stiffness and stability. The analyses confirm that material selection is a decisive factor in the effectiveness of generative gear design, as an appropriate choice contributes to an improved balance between weight, stiffness, and production cost. The presented framework integrates shape optimization, load evaluation, and material constraints to support the development of innovative, efficient, and manufacturable gear geometries for modern engineering applications.

The subject of the research presented in this article is the dimensional optimisation of the box structure of the main girder for overhead cranes, with the aim to reduce the main girder’s own weight. Described are the applied optimisation methods and also the problems arising during the optimisation process. Loss of shape stability is analysed in more detail, as well as the methods determined for a constructional proposal of the girder cross-section. The developed optimisation procedure is a combination of the calculations, performed in the MS Excel environment, with the simulation of a parametrically modelled girder realised using Dassault Systèmes SolidWorks software v. 2023. Using the example of optimisation of an overhead crane girder with a lifting capacity of 50 tons, the effectiveness of the proposed optimisation procedure is declared, where the existing overhead crane box girder is compared with the optimised cross-section of the box girder.

The subject of investigation presented in this article is a filling and draining system of the ship lock installed in the Gabčíkovo Waterworks. This article describes the operation and construction of the special regulation segments, i.e., the check gates that are situated in the ship locks. After the failure and replacement of the original check gate with the new, improved one, the strain gauge sensors were applied to the new check gate in order to determine stress distribution on the segment surface as well as the loading of the actuating arms. The application method and application places of the strain gauge sensors are described in detail. The performed measurements detected the occurrence of additional motional resistances during the opening and closing of the check gate. These resistances caused a partial non-functionality of the original check gate actuating mechanism.

This article focuses on cranes that are moving on a fixed crane track. There are specific problems and malfunctions arising during the operation of these cranes caused mainly by the crane skewing phenomenon. Crane skewing induces undesirable additional forces as a result of force contact between the crane wheel flange and the head of the crane track rail. This negative phenomenon induces additional stress in the crane construction as well as wear of the crane components and, finally, a global reduction of the crane operational durability and reliability. There is described in this article a methodology and data processing for the experimental measurement targeted on the crane skewing, namely in the case of a bridge crane installed in a laboratory. The crane skewing phenomenon was experimentally induced by an intentional disruption of speed synchronization of the crane travel drives. The intensity of the crane skewing was measured by means of the strain gauge sensors. A suitable application of the measuring sensors, together with the utilization of the drive control algorithm, enables efficiency to eliminate crane skewing and also prevent its occurrence.

In this contribution, a technique of axial centering of cast-iron moulds, e.g. the so-called “rail system” as suggested by KonCAD CZ s.r.o. for the application of horizontal centrifugal metal casting process, is described, evaluated, and finally not recommended for practical use. The...