The paper presents a mathematical model for calculating cutting forces during the machining of 16MnCr5 steel using the Sandvik CNMG 120408 16P25T tool. The modeling process involved the use of a test rig constructed based on the 16Д25 machine, which enabled the measurement of real values of spindle speed, longitudinal feed, cutting depth, and cutting forces. The results transmitted to a computer through the LTR-EU-8 workstation, equipped with galvanic isolated LTR modules and a synchronization interface. Based on the experimental results, the theoretical model demonstrated a deviation from actual measurements of no more than 4.72%. The study provides evidence that the cutting force calculations commonly presented by leading tool manufacturers are inherently overestimated. he difference in cutting forces can be 9%.
{"title":"Development of a Parametric Model for Calculating Cutting Forces in External Cylindrical Turning of 16MNCR5 Steel","authors":"I. P. Balabanov, Yuliya Balabanova, Agasi Agayev","doi":"10.4028/p-4xsctu","DOIUrl":"https://doi.org/10.4028/p-4xsctu","url":null,"abstract":"The paper presents a mathematical model for calculating cutting forces during the machining of 16MnCr5 steel using the Sandvik CNMG 120408 16P25T tool. The modeling process involved the use of a test rig constructed based on the 16Д25 machine, which enabled the measurement of real values of spindle speed, longitudinal feed, cutting depth, and cutting forces. The results transmitted to a computer through the LTR-EU-8 workstation, equipped with galvanic isolated LTR modules and a synchronization interface. Based on the experimental results, the theoretical model demonstrated a deviation from actual measurements of no more than 4.72%. The study provides evidence that the cutting force calculations commonly presented by leading tool manufacturers are inherently overestimated. he difference in cutting forces can be 9%.","PeriodicalId":17714,"journal":{"name":"Key Engineering Materials","volume":"22 12","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140739112","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
In the article, the interaction of the coefficient of friction for friction pairs operating under conditions of abrasive wear is considered, depending on a number of factors. Thus, the friction coefficient is one of the main indicators characterizing the performance of friction nodes. Analytical expressions obtained based on the calculation of the results of the conducted tests using mathematical statistical and mathematical methods allow to determine the coefficient of friction and allow the designer to effectively choose the material and oils before designing.
{"title":"Study of the Dependence of the Friction Force and Coefficient of the Abrasive in the Metal Contact Zone on Various Factors","authors":"Yehya Emenov, Savalan Kerimov, Samaya Baghirova","doi":"10.4028/p-p9ejye","DOIUrl":"https://doi.org/10.4028/p-p9ejye","url":null,"abstract":"In the article, the interaction of the coefficient of friction for friction pairs operating under conditions of abrasive wear is considered, depending on a number of factors. Thus, the friction coefficient is one of the main indicators characterizing the performance of friction nodes. Analytical expressions obtained based on the calculation of the results of the conducted tests using mathematical statistical and mathematical methods allow to determine the coefficient of friction and allow the designer to effectively choose the material and oils before designing.","PeriodicalId":17714,"journal":{"name":"Key Engineering Materials","volume":"36 4","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140737837","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Dame Alemayehu Efa, H. Lemu, E. M. Gutema, Mahesh Gopal
The goal of this research is to examine the influence of temperature affects the forging of a rectangular billet of AISI 4120 alloy steel using the 3D Deform version 11 software. The simulation was performed with 0.3 coefficient of friction on a metal forming (lubricated) process and the part is intended for application in aerospace and oil and gas industries. Three modules of deform software were defined to execute the simulation: pre-processing, simulation, and post-processing. The pre-processing in forging employed standard data— material selection, billet drawing, top and bottom dies design, meshing and simulation control. After 120 steps, the post-process estimation of deformation temperature, effective strain and stress, total velocity, and total displacement were obtained on the billet of material at temperatures of 800o C, 1000o C, and 1200° C. The results show that when forging temperatures climb, effective strain and stress decrease, total displacement and velocity decrease, and the final temperature increases.
{"title":"Analyzing the Effect of Temperature on Alloy Steel Forging Simulation Using Finite Element Simulation","authors":"Dame Alemayehu Efa, H. Lemu, E. M. Gutema, Mahesh Gopal","doi":"10.4028/p-a6inh6","DOIUrl":"https://doi.org/10.4028/p-a6inh6","url":null,"abstract":"The goal of this research is to examine the influence of temperature affects the forging of a rectangular billet of AISI 4120 alloy steel using the 3D Deform version 11 software. The simulation was performed with 0.3 coefficient of friction on a metal forming (lubricated) process and the part is intended for application in aerospace and oil and gas industries. Three modules of deform software were defined to execute the simulation: pre-processing, simulation, and post-processing. The pre-processing in forging employed standard data— material selection, billet drawing, top and bottom dies design, meshing and simulation control. After 120 steps, the post-process estimation of deformation temperature, effective strain and stress, total velocity, and total displacement were obtained on the billet of material at temperatures of 800o C, 1000o C, and 1200° C. The results show that when forging temperatures climb, effective strain and stress decrease, total displacement and velocity decrease, and the final temperature increases.","PeriodicalId":17714,"journal":{"name":"Key Engineering Materials","volume":"6 5","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140739464","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
N. Rasulov, Elgun Shabiyev, G. Damirova, M. Alakbarov, Yusif Huseynov
The work addresses the issues of increasing processing accuracy and productivity by controlling technological connections that act during the formation of shaped surfaces by grinding and plastic deformation, presents the main indicators of the quality of teeth on the working surface, provided by the developed technology, with a decrease in the maximum value of the actual cutting depth by more than 1.5 times when grinding toothed surfaces by copying, determined influence of the position of the workpiece on the accuracy of the pitch and half-angles of the profile for rolling threads of high precision by radial feed, the purpose of which is movement and measurement, design features determined of rollers for thread rolling on workpieces with low rigidity with tangential feed, the parameters of their threads, including the functional and structural relationship of the helix angles with the dimensions of the rolled thread.
{"title":"Increasing the Efficiency of Forming Complex Rotating Surfaces with the Controlling of Technological Connections","authors":"N. Rasulov, Elgun Shabiyev, G. Damirova, M. Alakbarov, Yusif Huseynov","doi":"10.4028/p-jc7ovu","DOIUrl":"https://doi.org/10.4028/p-jc7ovu","url":null,"abstract":"The work addresses the issues of increasing processing accuracy and productivity by controlling technological connections that act during the formation of shaped surfaces by grinding and plastic deformation, presents the main indicators of the quality of teeth on the working surface, provided by the developed technology, with a decrease in the maximum value of the actual cutting depth by more than 1.5 times when grinding toothed surfaces by copying, determined influence of the position of the workpiece on the accuracy of the pitch and half-angles of the profile for rolling threads of high precision by radial feed, the purpose of which is movement and measurement, design features determined of rollers for thread rolling on workpieces with low rigidity with tangential feed, the parameters of their threads, including the functional and structural relationship of the helix angles with the dimensions of the rolled thread.","PeriodicalId":17714,"journal":{"name":"Key Engineering Materials","volume":"157 2","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140740207","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Arif Mammadov, Nizami Ismayilov, Elxan Mammadov, Muxtar Huseynov
The importance of creating specialized production sites to meet the needs of shipbuilding and ship repair enterprises of Azerbaijan in metal billets is substantiated. Technical, technological and organizational measures for the specialization of the existing production sites of Baku Steel Company LLC for the production of shipbuilding steels are recommended. The ways of mastering the production of continuously cast billets and sheet-rolling technologies from shipbuilding steels are shown.For this purpose, the need to install a continuous casting machine (CCM) in Baku Steel Company LLC is substantiated and the advantages of manufacturing steel billets on this machine are shown. It is determined that in order to reduce the overall dimensions of the caster, its radius of curvature should be 10.2 m. It is shown that the rational value of the radius of curvature reduces the probability of defects on the blanks during crystallization and makes it possible to obtain blanks of various profiles.It is shown that the combined use of EMF and hydrocarbons can reduce the defects of blanks by 2-3 times, increase the zones of equiaxial crystals by 50-80%, significantly reduce axial porosity and liquation, increase the casting speed of liquid steel by 20-30% and reduce the metal consumption of equipment by 2 times. The introduction of technologies for electromagnetic mixing and vacuuming of liquid steel makes it possible to expand the production of alloy steels for the needs of shipbuilding and ship repair enterprises.
{"title":"Study of the Possibility of Production of Continuously Cast Billets from Shipbuilding Steels","authors":"Arif Mammadov, Nizami Ismayilov, Elxan Mammadov, Muxtar Huseynov","doi":"10.4028/p-8ys0gg","DOIUrl":"https://doi.org/10.4028/p-8ys0gg","url":null,"abstract":"The importance of creating specialized production sites to meet the needs of shipbuilding and ship repair enterprises of Azerbaijan in metal billets is substantiated. Technical, technological and organizational measures for the specialization of the existing production sites of Baku Steel Company LLC for the production of shipbuilding steels are recommended. The ways of mastering the production of continuously cast billets and sheet-rolling technologies from shipbuilding steels are shown.For this purpose, the need to install a continuous casting machine (CCM) in Baku Steel Company LLC is substantiated and the advantages of manufacturing steel billets on this machine are shown. It is determined that in order to reduce the overall dimensions of the caster, its radius of curvature should be 10.2 m. It is shown that the rational value of the radius of curvature reduces the probability of defects on the blanks during crystallization and makes it possible to obtain blanks of various profiles.It is shown that the combined use of EMF and hydrocarbons can reduce the defects of blanks by 2-3 times, increase the zones of equiaxial crystals by 50-80%, significantly reduce axial porosity and liquation, increase the casting speed of liquid steel by 20-30% and reduce the metal consumption of equipment by 2 times. The introduction of technologies for electromagnetic mixing and vacuuming of liquid steel makes it possible to expand the production of alloy steels for the needs of shipbuilding and ship repair enterprises.","PeriodicalId":17714,"journal":{"name":"Key Engineering Materials","volume":"7 6","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140739332","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
The study aims to investigate the engineering properties of concrete incorporating water purification sludge (WPS). The design compressive strengths of concrete are 14 MPa and 21 MPa at 28 days. The rates of WPS for replacing natural aggregate are 0%, 30%, and 60%. The test results show that the slump and unit weight of fresh concrete decrease with the increase of the WPS content, and the development of concrete compressive strength and splitting strength also have the same phenomenon. The replacement ratio of WPS reaches 60%, and the ultrasonic pulse velocity is less than 3000 m/sec, meaning that the quality of the concrete is poor. Concrete with WPS has lower resistance to permeability than that control concrete, which means the durability of the concrete presents lower than that of control concrete. The concrete incorporating WPS has lower compressive strength and durability because of existing WPS particles in the interfacial transition zone around the aggregate.
{"title":"Engineering Properties of Concrete Incorporating Water Purification Sludge","authors":"Chung Hao Wu, Wei Ting Lin, Shao Ting Hu","doi":"10.4028/p-a4iw3h","DOIUrl":"https://doi.org/10.4028/p-a4iw3h","url":null,"abstract":"The study aims to investigate the engineering properties of concrete incorporating water purification sludge (WPS). The design compressive strengths of concrete are 14 MPa and 21 MPa at 28 days. The rates of WPS for replacing natural aggregate are 0%, 30%, and 60%. The test results show that the slump and unit weight of fresh concrete decrease with the increase of the WPS content, and the development of concrete compressive strength and splitting strength also have the same phenomenon. The replacement ratio of WPS reaches 60%, and the ultrasonic pulse velocity is less than 3000 m/sec, meaning that the quality of the concrete is poor. Concrete with WPS has lower resistance to permeability than that control concrete, which means the durability of the concrete presents lower than that of control concrete. The concrete incorporating WPS has lower compressive strength and durability because of existing WPS particles in the interfacial transition zone around the aggregate.","PeriodicalId":17714,"journal":{"name":"Key Engineering Materials","volume":"80 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140736348","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Metallurgical indicators of 32CrMoV12-10 brand steel, which is a convenient construction material, were investigated and the main characteristics of the honing operation, especially the main factors affecting the geometric shape and size accuracy of the detail surface were determined based on these data. The physical-mechanical indicators and analysis of the chemical composition of the material were determined, analyzes were carried out to improve the technological and operational properties, the factors influencing the quality and the optimal processing conditions were determined. As a result, the selection of technological methods for obtaining high-quality internal cylindrical surfaces, the characteristics of surface formation and the regularity of selection of processing mode parameters were investigated.
{"title":"Characteristics of Quality Formation in Processing of 32CrMoV12-10 Steel by Honing","authors":"Sarvan Aziz","doi":"10.4028/p-8bwr6u","DOIUrl":"https://doi.org/10.4028/p-8bwr6u","url":null,"abstract":"Metallurgical indicators of 32CrMoV12-10 brand steel, which is a convenient construction material, were investigated and the main characteristics of the honing operation, especially the main factors affecting the geometric shape and size accuracy of the detail surface were determined based on these data. The physical-mechanical indicators and analysis of the chemical composition of the material were determined, analyzes were carried out to improve the technological and operational properties, the factors influencing the quality and the optimal processing conditions were determined. As a result, the selection of technological methods for obtaining high-quality internal cylindrical surfaces, the characteristics of surface formation and the regularity of selection of processing mode parameters were investigated.","PeriodicalId":17714,"journal":{"name":"Key Engineering Materials","volume":"102 4","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140736029","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Subhan Namazov, Ramesh K. Agarwal, Shanmugam Thillikkani
{"title":"Structural Metals and Building Materials","authors":"Subhan Namazov, Ramesh K. Agarwal, Shanmugam Thillikkani","doi":"10.4028/b-sdo9bw","DOIUrl":"https://doi.org/10.4028/b-sdo9bw","url":null,"abstract":"","PeriodicalId":17714,"journal":{"name":"Key Engineering Materials","volume":"37 4","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140736554","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
In this article, technological parameters such as cutting speed, feed rate and depth of cut and their relationships with average power are investigated and modelled using statistical design of experiments. This allows a quantitative and qualitative description of the relationship between average power and process parameters. The analytical knowledge gained from the tests provides the conditions for optimising the energy consumption of the turning process.
{"title":"Modelling of Turning Process for Prediction of Energy Consumption","authors":"Ilgar Abbasov, M. Suleymanov, Arastun Mammadov","doi":"10.4028/p-xb2rae","DOIUrl":"https://doi.org/10.4028/p-xb2rae","url":null,"abstract":"In this article, technological parameters such as cutting speed, feed rate and depth of cut and their relationships with average power are investigated and modelled using statistical design of experiments. This allows a quantitative and qualitative description of the relationship between average power and process parameters. The analytical knowledge gained from the tests provides the conditions for optimising the energy consumption of the turning process.","PeriodicalId":17714,"journal":{"name":"Key Engineering Materials","volume":"72 4","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140740836","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Two generalized cutting schemes predetermining the machining error formation mechanism are distinguished: contour machining, when the profile of the machined surface is formed by the corresponding tool path - contour machining; profile machining, when the profile of the machined surface is formed by the corresponding tool profile - shaped tool machining. For the trajectory scheme, the known force relations are generalized to a spatial curvilinear trajectory. Generalized dependencies for the cutting force components of form, slotted, cut-off and groove cutters are derived for the profile scheme. The evaluation of the adequacy of the proposed model for cutting force components is carried out on the basis of a specially conducted experimental research of the profile turning process with direct measurement of forces at different levels of varying technological factors. Thus, the developed dependences of the coordinate components of cutting forces on technological factors (parameters of cutting conditions, strength properties of the processed material, deformation properties of the technological system, etc.) allow using them for the practical application of machining error models in the matrix theory of multitool machining accuracy.
{"title":"Models of Cutting Forces in the Matrix Theory of Multitool Machining Accuracy","authors":"Nizami Yusubov, H. Abbasova","doi":"10.4028/p-bw48sb","DOIUrl":"https://doi.org/10.4028/p-bw48sb","url":null,"abstract":"Two generalized cutting schemes predetermining the machining error formation mechanism are distinguished: contour machining, when the profile of the machined surface is formed by the corresponding tool path - contour machining; profile machining, when the profile of the machined surface is formed by the corresponding tool profile - shaped tool machining. For the trajectory scheme, the known force relations are generalized to a spatial curvilinear trajectory. Generalized dependencies for the cutting force components of form, slotted, cut-off and groove cutters are derived for the profile scheme. The evaluation of the adequacy of the proposed model for cutting force components is carried out on the basis of a specially conducted experimental research of the profile turning process with direct measurement of forces at different levels of varying technological factors. Thus, the developed dependences of the coordinate components of cutting forces on technological factors (parameters of cutting conditions, strength properties of the processed material, deformation properties of the technological system, etc.) allow using them for the practical application of machining error models in the matrix theory of multitool machining accuracy.","PeriodicalId":17714,"journal":{"name":"Key Engineering Materials","volume":"13 2","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140739178","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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