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Influence of magneto-abrasive machining on the characteristics of the surface layer of flat parts 磁磨料加工对平面零件表层特性的影响
Pub Date : 2022-12-29 DOI: 10.20535/2521-1943.2022.6.3.265948
D. Dzhulii, V. Maiboroda, Oleksii Burikov
The paper presents the study of the influence of the process of magneto-abrasive machining (MAM) on the characteristics of the surface layers of flat surfaces of parts made of ferromagnetic material U9 by machining with end-type heads based on high-power permanent magnets that form a magneto-abrasive tool of the "brush" type. For estimation of the influence of the process of magneto-abrasive machining on the surface layer, the parameters of surface hardness were analyzed after the machining of test samples with different powders and under different modes. The degree of influence of the MAM on the surface, both in terms of the hardness of the surface layer and the deformation of samples due to compressive residual stresses arising as a result of machining, was studied. The estimation of the state of the surface layer was performed by the change in hardness after machining, the magnitude of the degree of hardening, to some extent, by the parameters of roughness. The control of changes in internal residual stresses formed in the surface layers of samples due to the interaction of powder particles with the surface during machining was carried out according to the degree of their deformation after MAM. It was found that due to MAM, internal compressive stresses of 30–100 MPa arise in the near-surface layer of the material of the samples, while the magnitude of the stresses varied in inverse dependency, that is, with an increase in the working gap, in the vast majority of cases, a decrease in the magnitude of the stresses was observed. It was shown that the depth of the hardened layer under different machining conditions is up to 200 µm or more, and the strengthening coefficient varies from 10 to 40%.
本文研究了用基于大功率永磁体的端头加工铁磁材料U9零件,形成“刷”型磁研磨工具时,磁研磨加工(MAM)工艺对其平面表层特性的影响。为了估计磁磨料加工过程对表面层的影响,分析了不同粉末和不同模式下试样加工后的表面硬度参数。研究了MAM对表面的影响程度,包括表面层的硬度和由于机械加工产生的压缩残余应力引起的样品变形。表面层状态的估计是通过机械加工后硬度的变化、硬化程度的大小,在某种程度上通过粗糙度参数来进行的。根据MAM后的变形程度,对加工过程中由于粉末颗粒与表面的相互作用而在样品表面层中形成的内部残余应力的变化进行控制。研究发现,由于MAM,在样品材料的近表面层中产生了30–100 MPa的内部压应力,而应力的大小呈反比变化,即随着工作间隙的增加,在绝大多数情况下,观察到应力的幅度减小。研究表明,在不同的加工条件下,硬化层的深度可达200µm或更大,强化系数从10%到40%不等。
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引用次数: 0
Application of erosion dimensional treatment methods for creation transversal fasteners in “metal-composite” joints 侵蚀尺寸处理方法在“金属复合材料”接头中产生横向紧固件的应用
Pub Date : 2022-12-29 DOI: 10.20535/2521-1943.2022.6.3.264786
I. Taranenko
At design of high-loaded units of engineering objects, especially such as articles of aero-space engineering, the problem of creation of reliable joints between metal and composite articles having predefined strength and ability to fulfill given functions appears.Development and grounding of selection of structural-manufacturing solutions of “metal-composite” joints with transversal fastening elements is selected as the objective of studying.As the object for studying possible structural-manufacturing solutions of “metal-composite” joints that use transversal fastening elements which are embedded to composite and attached to metal article or produced on its surface. Three types of fastening micro-elements are considered, i.e. pyramidal monolithic, cylindrical and sheet-formed, also different technologies of fastening elements production are considered too.Mass of typical flat article with micro-pins at given load-carrying ability of “metal-composite joint” was esti-mated for above-mentioned types of micro-fasteners.Such quantitative indexes of manufacturability as labor-intensity and energy consumption of fastening elements production were considered as results of studies.Approach to comparison methods of fastening elements manufacturing is suggested. This approach is based on analysis of correspondent numerical specific indexes of labor-intensity and energy consumption. These indexes are com-pared for micro-pins which are assumed to be produced of aluminum, titanium alloys and stainless steels.Distinctive feature of suggested model of analysis is taking into consideration both main and auxiliary techno-logical operations, which influence significantly on manufacturing labor-intensity and duration. Process of classical milling with cylindrical and disc mills is compared with up-to-date methods of electro-erosion cutting with wire.Recommendations for selection shape, type and arrangement scheme of micro-fasteners on article surface and exact manufacturing process of micro-pins production at given material are formulated as conclusions.
在工程物体的高载荷单元的设计中,特别是在航空航天工程的物品中,出现了在具有预定强度和实现给定功能的能力的金属和复合材料物品之间建立可靠接头的问题。选择具有横向紧固元件的“金属复合材料”接头的结构制造解决方案的开发和选择作为研究目标。作为研究“金属-复合材料”接头可能的结构制造解决方案的对象,该接头使用嵌入复合材料并连接到金属制品或在其表面上生产的横向紧固元件。考虑了三种类型的紧固微元件,即锥形单片、圆柱形和片状,并考虑了不同的紧固元件生产技术。在给定的“金属复合接头”承载能力下,对上述类型的微型紧固件的典型带微型销的平面制品的质量进行了估算。将紧固元件生产的劳动强度和能耗等可制造性的定量指标视为研究结果。提出了紧固件制造方法的比较方法。该方法是基于对相应的劳动强度和能源消耗的具体数字指标的分析。这些指标是针对假设由铝、钛合金和不锈钢制成的微型引脚进行比较的。所提出的分析模型的显著特点是同时考虑了主要和辅助技术操作,这些操作对制造业劳动强度和持续时间有显著影响。将传统的圆柱铣刀和圆盘铣刀的铣削工艺与最新的金属丝电蚀切削方法进行了比较。对制品表面微型紧固件的形状、类型和布置方案的选择以及在给定材料下生产微型销的精确制造工艺提出了建议,作为结论。
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引用次数: 0
Analysis of Available Data and Estimation of Energy Supply of Mechanical Processing 机械加工的可用数据分析与能量供应估算
Pub Date : 2022-12-29 DOI: 10.20535/2521-1943.2022.6.3.267250
V. Lavrinenko, V. Solod
The issue of energy efficiency of machining processes has been the focus of attention for the last 50 years. This is due to the fact that in comparison with other industries, metallurgy and mechanical engineering are characterized by a high level of energy intensity of products.Analysis of available in the literature indicators of energy costs of processing processes and determination of consistent data from these indicators.Establishing an analytical relationship between the grinding energy and the energy required for melting the finishing material.It is determined that the cutting energy of the material during chip for­mation is close to the energy required for melting the metal, and the excess amount of spent grinding energy is spent on friction between the chips and the grinding wheel. It is shown that in the literature there are data on the energy consumption of different treatments: turning - 2 kJ/cm3, milling - 9 kJ/cm3, grinding - 60 kJ/cm3, electrospark treatment - 3000 kJ/cm3. At the same time, the specific energy consumption of steel grinding is 60 kJ/cm3. And the specific heat of fusion of steel is 0.64 kJ/cm3. As a result, 100 times more heat is pumped into the steel during grinding than is needed to melt it. That is, there is a contradiction.To find ways to resolve this contradiction, it is more accurate to estimate the specific energy consumption of diamond-abrasive machining of superhard materials through additional consideration, in addition to productivity and effective machining power, wear of the working layer of the wheel.
近50年来,机械加工过程的能源效率问题一直是人们关注的焦点。这是因为与其他行业相比,冶金和机械工程的特点是产品的能源强度很高。分析文献中可用的能源成本加工过程指标,并从这些指标中确定一致的数据。建立研磨能量与精加工材料熔化所需能量之间的解析关系。确定了切屑形成过程中材料的切削能量与熔化金属所需的能量接近,多余的磨削能量消耗在切屑与砂轮之间的摩擦上。结果表明,在文献中有不同处理的能耗数据:车削- 2 kJ/cm3,铣削- 9 kJ/cm3,磨削- 60 kJ/cm3,电火花处理- 3000 kJ/cm3。同时,钢材磨削的比能耗为60 kJ/cm3。钢的熔化比热为0.64 kJ/cm3。因此,在研磨过程中,泵入钢的热量是熔化钢所需热量的100倍。也就是说,存在矛盾。为了找到解决这一矛盾的方法,除了考虑生产率和有效加工功率外,还要考虑砂轮工作层的磨损,对超硬材料的金刚石-磨料加工的比能耗进行更准确的估计。
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引用次数: 0
Using the functional approach in the development of hybrid processes in engineering: practical aspects 在工程混合过程开发中使用功能方法:实践方面
Pub Date : 2022-12-29 DOI: 10.20535/2521-1943.2022.6.3.269900
O. Salenko, S. Klimenko, Vadum Orel, Volodymyr Kholodny, Natalya Gavrushkevich
The principles of creating hybrid processing processes based on the functional approach are given. The base of this approach, its theoretical aspects are given in the first part of the article. The practical application of the approaches is reflected in specific scientific and technical problems in the problem of high-quality cleaning of the surface from various adhesive coatings, the use of methods for obtaining holes and perforations in workpieces from metals and composite materials, as well as in the problem of contour cutting of plates from superhard sintered materials. It is shown that the use of a functionally oriented approach makes it possible to identify such combinations of force and energy effects that make it possible to process even those materials that are considered difficult to process or not machinable.Samples of cleaned surfaces, cuts of superhard materials, holes in honeycomb systems of aerospace engineering are presented. 
给出了基于函数方法创建混合处理过程的原理。文章的第一部分介绍了这种方法的基础及其理论方面。这些方法的实际应用反映在特定的科学和技术问题上,这些问题包括高质量地清洁各种粘合涂层的表面,使用金属和复合材料在工件中获得孔和穿孔的方法,以及超硬烧结材料的板的轮廓切割问题。研究表明,使用面向功能的方法可以识别力和能量效应的组合,从而可以加工那些被认为难以加工或不可加工的材料。介绍了航空航天工程中清洁表面、超硬材料切口、蜂窝系统中的孔的样品。
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引用次数: 0
Hot extrusion of high carbon steel cone hollow products 热挤压高碳钢锥形中空制品
Pub Date : 2022-12-29 DOI: 10.20535/2521-1943.2022.6.3.269897
V. Kaliuzhnyi, Leyla Aliieva, Oleksandr Yarmolenko, S. Sytnyk
The work is devoted to researching a new method of hot direct-reverse extrusion of hollow conical products from high-carbon steel and determinated parameters for technological design. The considered method makes it possible to obtain in one step hollow products with different wall thickness in height, while the wall thickness in the upper part of the product can be greater than the thickness in the bottom part. The dimensions of the initial workpiece are determined by modeling using the finite element method, which ensures the simultaneous flow of metal in the forward and reverse directions during the process of forming the product, which reduces the deformation force. The use of this method also leads to a decrease in the heating of the deforming tool due to a decrease in the contact area of the deformed workpiece with the tool. The strain rate is determined to ensure the temperature interval of extrusion. The dependencies of the force of extrusion, removal of the punch from the deformed workpiece, pushing the product out of the matrix on the movement of the corresponding tool are established. The final shape and dimensions of the product with the distribution of temperature and deformations were found. For the maximum amount of extrusion force, the distributions of specific forces on the contacting surfaces of the punch, matrix, ejector and stress on the volume of the deformed workpiece were found. According to the obtained data, the technology of direct-reverse extrusion can be developed and implemented on universal press equipment, which has high productivity due to the reduction of the number of stamping steps. The design of the stamp for extruding products of certain sizes with forced cooling of the matrix is given. 
研究了一种由高碳钢直接反挤压空心圆锥产品的新方法,并确定了工艺设计参数。所考虑的方法可以在一步中获得具有不同高度壁厚的中空产品,而产品上部的壁厚可以大于底部的厚度。初始工件的尺寸是通过使用有限元方法建模来确定的,这确保了在产品成型过程中金属在正向和反向上同时流动,从而减少了变形力。该方法的使用还由于变形工件与工具的接触面积的减小而导致变形工具的加热的减小。应变速率的确定是为了确保挤压的温度间隔。建立了挤压力、从变形工件上移除冲头、将产品推出基体对相应工具运动的依赖关系。发现了产品的最终形状和尺寸以及温度和变形的分布。在挤压力最大的情况下,发现了冲头、基体、顶出器接触面上的比力分布以及变形工件体积上的应力分布。根据获得的数据,直接反向挤压技术可以在通用冲压设备上开发和实施,由于冲压步骤的减少,该设备具有较高的生产率。给出了在基体强制冷却条件下挤压一定尺寸产品的模具设计。
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引用次数: 0
Calculation and experimental procedure for determining the modulus of elasticity of porous coatings on a substrate during bending. Part 2. Experimental research 测定基底上多孔涂层弯曲时弹性模量的计算和实验程序。第2部分。实验研究
Pub Date : 2022-12-29 DOI: 10.20535/2521-1943.2022.6.3.262805
Marianna Dyman, A. Moltasov, Serhii Kaliuzhnyi
As it was mentioned in the first part of this work, to determine the modulus of elasticity of one of the layers of a double-layer beam during bending, it is necessary to know the modulus of elasticity of the other layer and the bending stiffness of the entire section. Therefore, the purpose of the presented part of the work is to experimentally establish the specified characteristics of coated samples of rectangular cross-section and substrate without coating during three-point bending. The results of experimental studies of elastic-geometric characteristics during bending of samples with coatings of VT1-00 and KTC-110 alloys, applied to a substrate of VT6 alloy by microplasma sputtering, with different degrees of porosity, are presented. Analytical calculations of the modulus of elasticity of the specified coatings were carried out, the results of which make it possible to establish the general regularities of its change depending on their degree of porosity.
正如本工作的第一部分所提到的,为了确定双层梁的一层在弯曲过程中的弹性模量,有必要知道另一层的弹性模量和整个截面的弯曲刚度。因此,本部分工作的目的是通过实验确定矩形截面的涂层样品和三点弯曲过程中无涂层基底的特定特性。给出了用微等离子体溅射法在VT6合金基体上涂覆VT1-00和KTC-110合金涂层的样品在弯曲过程中的弹性几何特性的实验研究结果。对指定涂层的弹性模量进行了分析计算,其结果使其能够根据孔隙率确定其变化的一般规律。
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引用次数: 0
Criterion of the limit state of composites materials 复合材料极限状态判据
Pub Date : 2022-12-29 DOI: 10.20535/2521-1943.2022.6.3.264783
M. Bobyr
The work proposes and substantiates a type of phenomenal criterion of composite material destruction at the stage of macro crack origination. It considers damageability and two mechanisms of destruction: tearing and slice. It describes that as parameter of damageability it can be taken specific energy of extra stresses or specific energy of diffusion. For proportionate and complex processes of metallic materials loading they result equally in practice. Methodologies of respective energetic parameters search are described. It is set threshold value of stress in the element of construction during the reach of it it is necessary to consider an accumulation of damage. It is described the methodology that describes interconnection between anisotropy factors and components of damage tensor.
提出并证实了复合材料宏观裂纹产生阶段的一种现象性破坏判据。它考虑了损伤性和两种破坏机制:撕裂和切片。说明损伤性参数可以取额外应力比能或扩散比能。对于比例和复杂的金属材料加载过程,它们在实践中是相同的。介绍了各自能量参数搜索的方法。在结构单元达到应力阈值时,需要考虑损伤的累积。介绍了描述各向异性因子与损伤张量分量之间相互联系的方法。
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引用次数: 0
Safety margin determination of the nuclear power plant reactor pressure vessel with taking into account warm pre-stress effect 考虑热预应力效应的核电站反应堆压力容器安全裕度的确定
Pub Date : 2022-12-29 DOI: 10.20535/2521-1943.2022.6.3.268515
Oleksii Ishchenko, M. Kryshchuk
In case for nuclear power plants long-term service operation over their design life, it is necessary to calculate reactor pressure vessel (RPV) strength and durability acknowledgment (static strength, strength under cyclic and seismic loads, brittle fracture resistance (BFR) include) the as one of the most important NPP structure. Usually, according to the brittle strength assessment, RPV resource is determined, that is, time of its subsequent safe operation. The purpose of this work is assessed BFR RPV at potential emergency accidents (EA) using the Ukrainian warm pre-stress approach. The calculated thermohydrodynamic parameters at EA were used to calculate the stress-strain state of the developed reactor finite element (FE) model. For researching, the most indicative scenarios were selected: where reactor is cooled at a high pressure. In RPV FE model cracks are modeled at the most dangerous places - welds and nozzle. Stress intensity factor (SIF) distribution along crack front and temperature for the most dangerous accidents in terms of BFR are presented in figures. Brittle strength condition is ensured during the nuclear power plants service operation for up to 60 years, which is more than 1.5 times more than the oldest Ukrainian power plant with VVER-1000. For some emergency accidents, warm pre-stress really significantly increased RPV safety margin, but for the most dangerous accidents, the results are the same as without taking into account WPS.
对于核电站在其设计寿命内的长期服务运行,有必要计算反应堆压力容器(RPV)强度和耐久性确认(静态强度、循环和地震载荷下的强度、脆性断裂抗力(BFR)),作为最重要的核电站结构之一。通常,根据脆性强度评估,确定RPV资源,即其后续安全运行的时间。本工作的目的是使用乌克兰温暖预应力方法评估潜在紧急事故(EA)下的BFR RPV。在EA下计算的热流体动力学参数用于计算所开发的反应堆有限元(FE)模型的应力-应变状态。为了进行研究,选择了最具指示性的场景:反应堆在高压下冷却。在RPV有限元模型中,裂纹是在最危险的地方建模的——焊缝和喷嘴。图中给出了以BFR表示的最危险事故的应力强度因子(SIF)沿裂纹前缘的分布和温度。在核电站长达60年的服务运行期间,确保了脆性强度条件,这是乌克兰最古老的VVER-1000核电站的1.5倍多。对于一些紧急事故,热预应力确实显著提高了RPV安全裕度,但对于最危险的事故,结果与不考虑WPS的情况相同。
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引用次数: 0
Applications of randomly selected sets of exact Voight's solutions for vibration of thin plates 随机选择的精确Voight解集在薄板振动中的应用
Pub Date : 2022-12-29 DOI: 10.20535/2521-1943.2022.6.3.263541
I. Orynyak, J. Bai, I. Kostiushko
The principally new method of selected exact solutions, SES, for plate vibration based on fundamental solutions of Voigt is suggested. In contrast to similar known methods, it employs the frequency dependent functions for both space coordinates. The sets of exact solutions which depends on some arbitrary chosen parameters are constructed. This allows to choose any number of exact solutions, while the required number of them depends on the boundary conditions which should satisfy in considered collocation points. The efficiency of method is demonstrated for the most unfavorable case of all sides clamped rectangular plate. Nevertheless, the accuracy is quite satisfactory for first six natural frequencies even for relatively small number of collocation boundary points, and testify about big prospects as to application for complex structures, different geometries, various boundary conditions. Additionally two variants of the Galerkin method are realized and compared. First one, employs the exponential functions, while the second one –the very popular beam functions. The calculation results show the superiority of first variant as in technical realization as in accuracy, and in further applications in structural mechanics.
在Voigt基本解的基础上,提出了一种新的选择板振动精确解的方法SES。与类似的已知方法不同,它对两个空间坐标都采用了频率相关函数。构造了依赖于一些任意选择的参数的精确解集。这允许选择任意数量的精确解,而所需的精确解的数量取决于所考虑的配置点中应满足的边界条件。对四边夹持矩形板的最不利情况,证明了该方法的有效性。然而,即使对于相对较少的配置边界点,前六个固有频率的精度也相当令人满意,并证明了在复杂结构、不同几何形状、各种边界条件下的应用前景广阔。此外,实现并比较了Galerkin方法的两种变体。第一种是采用指数函数,而第二种是非常流行的波束函数。计算结果表明,第一种变体在技术实现、精度以及在结构力学中的进一步应用方面都具有优越性。
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引用次数: 0
The structure of viscous liquid internal flows in tanks with damping baffles 带阻尼挡板的储罐中粘性液体内部流动的结构
Pub Date : 2022-12-29 DOI: 10.20535/2521-1943.2022.6.3.266603
V. Kovalev, Wei Chenyu
Modern moving objects containing large volumes of liquid need to ensure stability on the movement trajectory, reliability of control during maneuvers, as well as the ability to predict and prevent extreme movement conditions. The presented article provides review materials devoted to the research results into inertial flows of viscous incompressible fluid in tanks with internal damping baffles. In order to exert force on resonant excitations from the liquid side and to compensate for the instabilities of moving objects, the analysis and design of rational structures of influence means on currents is carried out.Among the most effective means of damping should be noted rigid internal baffles of various designs installed in tanks in the most likely areas where instabilities and sources of excitation of resonant fluid movements may occur. Flat rigid partitions, profiled permeable damping surfaces, perforated and retaining elements, enslavers of liquid due to surface tension forces, etc., require comprehensive and detailed study and analysis.
含有大量液体的现代运动物体需要确保运动轨迹的稳定性、操纵过程中的控制可靠性,以及预测和防止极端运动条件的能力。本文提供了关于粘性不可压缩流体在具有内部阻尼挡板的储罐中惯性流动的研究结果的综述材料。为了对液体侧的共振激励施加力,并补偿运动物体的不稳定性,对电流影响装置的合理结构进行了分析和设计。在最有效的阻尼方法中,应注意安装在储罐中的各种设计的刚性内部挡板,这些挡板最有可能发生共振流体运动的不稳定性和激励源。平面刚性隔板、异形可渗透阻尼表面、穿孔和保持元件、表面张力导致的液体奴役物等,都需要进行全面详细的研究和分析。
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引用次数: 0
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Mechanics and Advanced Technologies
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