Pub Date : 2023-09-15DOI: 10.17212/1994-6309-2023-25.3-137-151
Savendra Singh, Chetan Hirwani
Introduction: Recently, the use of natural fibers have been increased to replace the use of synthetic fibers to save our environment from waste disposal problems, natural fibers have a lower level of mechanical properties. The purpose of work: This study examines the effect of treating the surface and deeper layers of jute fiber on the mechanical behavior and characteristics of free vibrations of a composite material based on it. The methods of investigation: due to the uniform distribution of stresses in the WARP and WEFT directions, four-layer basket weave jute fibers were used in this study. Result and discussion: the mechanical and free vibration properties of composite materials are significantly improved when NaOH is applied to jute fibers because it eliminates the weak matrix material lignin and makes the fibers stiffer and stronger. However, increasing the percentage of NaOH and soaking time for the fibers in NaOH solution have little effect on these properties. The highest value of tensile strength and tensile modulus are found 50 ± 1.17 MPa and 1.94 ± 0.23 GPa respectively seen in case of basket weave jute fiber composite with 1 hour treatment. Tensile strength and tensile modulus increase about 12 % and 40 % over the stokes value, respectively. Similarly the value of flexural strength and flexural modulus are found 95 ± 1.17 MPa and 3.99 ± 0.23 GPa respectively in case of basket weave jute fiber composite with 1 hour treatment. It also shows the highest value of fundamental frequency 77.837 Hz.The presence of an O-H bond in the composite, as revealed by FTIR study, gives it a hydrophilic character and limits its use in humid environments. The fiber to matrix ratio is shown in SEM images.
{"title":"Free vibration and mechanical behavior of treated woven jute polymer composite","authors":"Savendra Singh, Chetan Hirwani","doi":"10.17212/1994-6309-2023-25.3-137-151","DOIUrl":"https://doi.org/10.17212/1994-6309-2023-25.3-137-151","url":null,"abstract":"Introduction: Recently, the use of natural fibers have been increased to replace the use of synthetic fibers to save our environment from waste disposal problems, natural fibers have a lower level of mechanical properties. The purpose of work: This study examines the effect of treating the surface and deeper layers of jute fiber on the mechanical behavior and characteristics of free vibrations of a composite material based on it. The methods of investigation: due to the uniform distribution of stresses in the WARP and WEFT directions, four-layer basket weave jute fibers were used in this study. Result and discussion: the mechanical and free vibration properties of composite materials are significantly improved when NaOH is applied to jute fibers because it eliminates the weak matrix material lignin and makes the fibers stiffer and stronger. However, increasing the percentage of NaOH and soaking time for the fibers in NaOH solution have little effect on these properties. The highest value of tensile strength and tensile modulus are found 50 ± 1.17 MPa and 1.94 ± 0.23 GPa respectively seen in case of basket weave jute fiber composite with 1 hour treatment. Tensile strength and tensile modulus increase about 12 % and 40 % over the stokes value, respectively. Similarly the value of flexural strength and flexural modulus are found 95 ± 1.17 MPa and 3.99 ± 0.23 GPa respectively in case of basket weave jute fiber composite with 1 hour treatment. It also shows the highest value of fundamental frequency 77.837 Hz.The presence of an O-H bond in the composite, as revealed by FTIR study, gives it a hydrophilic character and limits its use in humid environments. The fiber to matrix ratio is shown in SEM images.","PeriodicalId":42889,"journal":{"name":"Obrabotka Metallov-Metal Working and Material Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-09-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135437691","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}
Pub Date : 2023-09-15DOI: 10.17212/1994-6309-2023-25.3-19-35
Andrey Ilinykh, Aleksandr Pikalov, Vladimir Miloradovich, Marina Galay
Introduction. Rails’ grinding in the conditions of a railway track is a priority for extending its life cycle due to the timely removal of tread surface defects and formation of required transverse profile. Today, 14 RSHP-48 rail grinding trains are used in Russia. At the same time, most rail grinding trains are ending its service life. Therefore, the development of a fundamentally new rail grinding train with increased efficiency is an urgent task. Siberian transport university is working together with the Kaluga plant “Remputmash” to create a new rail grinding train named RSHP 2.0. The rail grinding train RSHP 2.0 is based on the technology of high-speed rail grinding, which is based on increasing working speed of rail grinding train by increasing rotational speed of grinding wheels and setting the angle of attack. The aim of this work is to study rails’ grinding modes on a specially designed installation URSH, which implements the technology of high-speed grinding rails by increasing speed of grinding wheels rotation up to 5,000 rpm. Research methods. Grinding wheel speed control was carried out by IT-5-ChM “Termit” electronic tachometer and “Megeon 18005” laser tachometer. The angle of attack of grinding wheel was measured by digital, three-axis accelerometer-inclinometer ATst 90. The force of pressing grinding wheel to the rail was evaluated by strain-resistive sensors M50-0.5-C3. The measurement of head rail transverse profile before and after grinding and evaluation of metal removal were carried out by a PR-03 rail profiler. The width of grinding track was controlled by ShTsTs-I-300-0.01 caliper. The surface roughness of rail sample after machining was measured by TR 200 portable instrument. Results and discussion. Based on research results of CRS, the parameters of the working equipment of designed grinding rail train, which implements the technology of high-speed rail grinding, the influence of grinding modes on the formation of the quality parameters of the machined rail surface are established, and the optimal values of the forces of pressing the grinding wheel to the rail are determined.
{"title":"Experimental studies of high-speed grinding rails modes","authors":"Andrey Ilinykh, Aleksandr Pikalov, Vladimir Miloradovich, Marina Galay","doi":"10.17212/1994-6309-2023-25.3-19-35","DOIUrl":"https://doi.org/10.17212/1994-6309-2023-25.3-19-35","url":null,"abstract":"Introduction. Rails’ grinding in the conditions of a railway track is a priority for extending its life cycle due to the timely removal of tread surface defects and formation of required transverse profile. Today, 14 RSHP-48 rail grinding trains are used in Russia. At the same time, most rail grinding trains are ending its service life. Therefore, the development of a fundamentally new rail grinding train with increased efficiency is an urgent task. Siberian transport university is working together with the Kaluga plant “Remputmash” to create a new rail grinding train named RSHP 2.0. The rail grinding train RSHP 2.0 is based on the technology of high-speed rail grinding, which is based on increasing working speed of rail grinding train by increasing rotational speed of grinding wheels and setting the angle of attack. The aim of this work is to study rails’ grinding modes on a specially designed installation URSH, which implements the technology of high-speed grinding rails by increasing speed of grinding wheels rotation up to 5,000 rpm. Research methods. Grinding wheel speed control was carried out by IT-5-ChM “Termit” electronic tachometer and “Megeon 18005” laser tachometer. The angle of attack of grinding wheel was measured by digital, three-axis accelerometer-inclinometer ATst 90. The force of pressing grinding wheel to the rail was evaluated by strain-resistive sensors M50-0.5-C3. The measurement of head rail transverse profile before and after grinding and evaluation of metal removal were carried out by a PR-03 rail profiler. The width of grinding track was controlled by ShTsTs-I-300-0.01 caliper. The surface roughness of rail sample after machining was measured by TR 200 portable instrument. Results and discussion. Based on research results of CRS, the parameters of the working equipment of designed grinding rail train, which implements the technology of high-speed rail grinding, the influence of grinding modes on the formation of the quality parameters of the machined rail surface are established, and the optimal values of the forces of pressing the grinding wheel to the rail are determined.","PeriodicalId":42889,"journal":{"name":"Obrabotka Metallov-Metal Working and Material Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-09-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135439626","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}
Pub Date : 2023-09-15DOI: 10.17212/1994-6309-2023-25.3-87-103
Alexey Ruktuev, Aleksandr Yurgin, Vladislav Shikalov, Arina Ukhina, Ivan Chakin, Evgeny Domarov, Gleb Dovzhenko
Introduction. Currently, a new class of materials, namely high-entropy alloys, is an active area of research. One of the areas of its application is the fabrication of protective coatings with high performance properties. The high-entropy alloy of CoCrFeNiMn composition is characterized by high ductility, which is retained both at elevated and cryogenic temperatures, as well as high thermal stability and, thus, can be considered as promising materials for protective coatings formation. At the same time, its disadvantages are low hardness and strength. It is known that the reinforcement of the CoCrFeNiMn high-entropy alloy with hardening particles is an effective way to improve the mechanical properties of coatings. It is assumed that the addition of hardening boride particles affects positively on the mechanical characteristics of the alloy. The aim of this work is to study the structural and phase states and wear resistance of coatings based on a CoCrFeNiMn high-entropy alloy reinforced with CrB particles. Coatings obtained by the method of non-vacuum electron-beam surfacing of powder mixtures with different mass ratios of CoCrNiMn metal powders to the CrB powder (100:0, 95:5, 90:10, 80:20, 70:30) are studied in this work. To investigate the structure and phase composition of the coatings, such methods as optical microscopy, scanning electron microscopy and X-ray diffraction analysis were applied. To study the elemental composition, energy-dispersive X-ray analysis was used. The mechanical properties were evaluated based on the microhardness measuring results. The wear resistance of the coatings was determined under conditions of dry sliding friction during reciprocating motion. Results and discussion. The addition of CrB powder to the surfacing mixture led to the formation of eutectic structures. When 5 wt. % CrB was added, a hypoeutectic structure is formed in the coating. An increase in the amount of CrB leads to the formation of coatings with a hypereutectic structure containing primary borides. The main phases found in the coatings are the fcc solid solution, and (Cr,Mn,Fe)2B, (Ni,Co,Mn)2B, CrB borides. All the studied coatings are characterized by an adhesive wear mechanism. The addition of 20 % and 30 % CrB to the surfacing mixture composition results in the wear resistance increase of the high-entropy alloy-based coatings by 3.6 and 6.1 times, respectively.
{"title":"Structure and properties of HEA-based coating reinforced with CrB particles","authors":"Alexey Ruktuev, Aleksandr Yurgin, Vladislav Shikalov, Arina Ukhina, Ivan Chakin, Evgeny Domarov, Gleb Dovzhenko","doi":"10.17212/1994-6309-2023-25.3-87-103","DOIUrl":"https://doi.org/10.17212/1994-6309-2023-25.3-87-103","url":null,"abstract":"Introduction. Currently, a new class of materials, namely high-entropy alloys, is an active area of research. One of the areas of its application is the fabrication of protective coatings with high performance properties. The high-entropy alloy of CoCrFeNiMn composition is characterized by high ductility, which is retained both at elevated and cryogenic temperatures, as well as high thermal stability and, thus, can be considered as promising materials for protective coatings formation. At the same time, its disadvantages are low hardness and strength. It is known that the reinforcement of the CoCrFeNiMn high-entropy alloy with hardening particles is an effective way to improve the mechanical properties of coatings. It is assumed that the addition of hardening boride particles affects positively on the mechanical characteristics of the alloy. The aim of this work is to study the structural and phase states and wear resistance of coatings based on a CoCrFeNiMn high-entropy alloy reinforced with CrB particles. Coatings obtained by the method of non-vacuum electron-beam surfacing of powder mixtures with different mass ratios of CoCrNiMn metal powders to the CrB powder (100:0, 95:5, 90:10, 80:20, 70:30) are studied in this work. To investigate the structure and phase composition of the coatings, such methods as optical microscopy, scanning electron microscopy and X-ray diffraction analysis were applied. To study the elemental composition, energy-dispersive X-ray analysis was used. The mechanical properties were evaluated based on the microhardness measuring results. The wear resistance of the coatings was determined under conditions of dry sliding friction during reciprocating motion. Results and discussion. The addition of CrB powder to the surfacing mixture led to the formation of eutectic structures. When 5 wt. % CrB was added, a hypoeutectic structure is formed in the coating. An increase in the amount of CrB leads to the formation of coatings with a hypereutectic structure containing primary borides. The main phases found in the coatings are the fcc solid solution, and (Cr,Mn,Fe)2B, (Ni,Co,Mn)2B, CrB borides. All the studied coatings are characterized by an adhesive wear mechanism. The addition of 20 % and 30 % CrB to the surfacing mixture composition results in the wear resistance increase of the high-entropy alloy-based coatings by 3.6 and 6.1 times, respectively.","PeriodicalId":42889,"journal":{"name":"Obrabotka Metallov-Metal Working and Material Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-09-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135439628","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}
Introduction. When studying the energy dissipation associated with internal friction in a weld, it is extremely important to choose a measurement technique, since the reliability and integrity of the data obtained depends on it. At the same time, it is necessary to investigate the change in internal friction depending on the presence of defects in the weld. Of the variety of methods for non-destructive testing of joints obtained by pressure welding, only ultrasonic is currently used. However, lightly oxidized lacks of welding penetration are not detected, which can be detected only in the presence of other defects accompanying it. Compounds of dissimilar materials are not controlled by ultrasound at all. Therefore, the development of non-destructive testing methods for such compounds is very relevant. The purpose of the work: to find a procedure for testing the quality of a welded joint in metals and alloys that will be a quick and simple alternative to the known methods of non-destructive testing, by measuring the energy dissipation in the weld of the sample by the static hysteresis loop method. The method of investigation is non-destructive quality control of the welded joint in metals and alloys by measuring the energy dissipation in the weld of the sample by the static hysteresis loop method. Results and discussion. It is established that with an increase in the lacks of welding penetration, the energy dissipation increases at the same values of the torque amplitude under static loading conditions. The rigidity of the qualitative welded joints remains constant, and the joints with lacks of welding penetration decrease with increasing torque amplitude. The relationship of strength with stiffness and damping ability obtained by the static hysteresis loop method is preserved for various structural states of the sample material.
{"title":"Study of energy dissipation and rigidity of welded joints obtained by pressure butt welding","authors":"Anatoly Maytakov, Alexey Grachev, Anatoly Popov, Sergey Li, Nadezhda Vetrova, Konstantin Plotnikov","doi":"10.17212/1994-6309-2023-25.3-104-116","DOIUrl":"https://doi.org/10.17212/1994-6309-2023-25.3-104-116","url":null,"abstract":"Introduction. When studying the energy dissipation associated with internal friction in a weld, it is extremely important to choose a measurement technique, since the reliability and integrity of the data obtained depends on it. At the same time, it is necessary to investigate the change in internal friction depending on the presence of defects in the weld. Of the variety of methods for non-destructive testing of joints obtained by pressure welding, only ultrasonic is currently used. However, lightly oxidized lacks of welding penetration are not detected, which can be detected only in the presence of other defects accompanying it. Compounds of dissimilar materials are not controlled by ultrasound at all. Therefore, the development of non-destructive testing methods for such compounds is very relevant. The purpose of the work: to find a procedure for testing the quality of a welded joint in metals and alloys that will be a quick and simple alternative to the known methods of non-destructive testing, by measuring the energy dissipation in the weld of the sample by the static hysteresis loop method. The method of investigation is non-destructive quality control of the welded joint in metals and alloys by measuring the energy dissipation in the weld of the sample by the static hysteresis loop method. Results and discussion. It is established that with an increase in the lacks of welding penetration, the energy dissipation increases at the same values of the torque amplitude under static loading conditions. The rigidity of the qualitative welded joints remains constant, and the joints with lacks of welding penetration decrease with increasing torque amplitude. The relationship of strength with stiffness and damping ability obtained by the static hysteresis loop method is preserved for various structural states of the sample material.","PeriodicalId":42889,"journal":{"name":"Obrabotka Metallov-Metal Working and Material Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-09-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135439627","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}
Pub Date : 2023-09-15DOI: 10.17212/1994-6309-2023-25.3-36-49
Denis Salikhyanov, Nikolay Michurov
Introduction. Bond strength between dissimilar materials is the most important characteristic of laminated composites, which determines the success of its development for industrial use. In order to develop the theory of joining materials by plastic deformation, it is proposed to perform computer simulation of joint deformation of representative volumes of dissimilar materials on a microscale and compare the parameters of the stress-strain state with the previously presented theoretical mechanism. The aim of this work is to analyze the stress-strain state of dissimilar materials under plastic deformation on a microscale and to establish the location of the onset of fracture of surface oxide films. To achieve this aim, the following tasks of the work are formulated: 1) to study the surface profiles of dissimilar materials to be bonded by plastic deformation; 2) to simulate by the finite element method (FE) the plastic deformation of contact surfaces of dissimilar materials on a microscale; 3) to study the stages of joint deformation of dissimilar materials on a microscale and verify of the theoretical mechanism. Research methodology. The study of three-dimensional topography and roughness was carried out on a Veeco Wyko NT1100 Optical Profiling System. Deform-3D FE simulation package was chosen as the main research tool. Aluminum alloys AMg3 and D16 were chosen as the materials under study. Results and discussion. In this work, computer FE simulating of the joint deformation of the surface layers of AMg3 and D16 alloys on a microscale was performed, an analysis of the surface profiles of materials after various types of processing was carried out, the parameters of the stress-strain state were studied and compared with the parameters of the theoretical mechanism. Based on the results of the comparison, the adequacy of the proposed theoretical mechanism was assessed, and the practical difficulties of theoretical simulation of the joint deformation of dissimilar materials on the microscale were noted. Microscale FE simulation made it possible to study the flow of plastic deformation in the near-surface layers of materials, as well as to identify areas of the most probable fracture of surface oxide films and, consequently, areas of primary bonding of dissimilar materials.
{"title":"The concept of microsimulation of processes of joining dissimilar materials by plastic deformation","authors":"Denis Salikhyanov, Nikolay Michurov","doi":"10.17212/1994-6309-2023-25.3-36-49","DOIUrl":"https://doi.org/10.17212/1994-6309-2023-25.3-36-49","url":null,"abstract":"Introduction. Bond strength between dissimilar materials is the most important characteristic of laminated composites, which determines the success of its development for industrial use. In order to develop the theory of joining materials by plastic deformation, it is proposed to perform computer simulation of joint deformation of representative volumes of dissimilar materials on a microscale and compare the parameters of the stress-strain state with the previously presented theoretical mechanism. The aim of this work is to analyze the stress-strain state of dissimilar materials under plastic deformation on a microscale and to establish the location of the onset of fracture of surface oxide films. To achieve this aim, the following tasks of the work are formulated: 1) to study the surface profiles of dissimilar materials to be bonded by plastic deformation; 2) to simulate by the finite element method (FE) the plastic deformation of contact surfaces of dissimilar materials on a microscale; 3) to study the stages of joint deformation of dissimilar materials on a microscale and verify of the theoretical mechanism. Research methodology. The study of three-dimensional topography and roughness was carried out on a Veeco Wyko NT1100 Optical Profiling System. Deform-3D FE simulation package was chosen as the main research tool. Aluminum alloys AMg3 and D16 were chosen as the materials under study. Results and discussion. In this work, computer FE simulating of the joint deformation of the surface layers of AMg3 and D16 alloys on a microscale was performed, an analysis of the surface profiles of materials after various types of processing was carried out, the parameters of the stress-strain state were studied and compared with the parameters of the theoretical mechanism. Based on the results of the comparison, the adequacy of the proposed theoretical mechanism was assessed, and the practical difficulties of theoretical simulation of the joint deformation of dissimilar materials on the microscale were noted. Microscale FE simulation made it possible to study the flow of plastic deformation in the near-surface layers of materials, as well as to identify areas of the most probable fracture of surface oxide films and, consequently, areas of primary bonding of dissimilar materials.","PeriodicalId":42889,"journal":{"name":"Obrabotka Metallov-Metal Working and Material Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-09-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135439625","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}
Introduction. The development of a cluster of hybrid metalworking systems in the machine tool industry is associated with a number of positive consequences. First, such systems help reduce production costs by optimizing the use of resources and energy. This is especially true in the face of increased competition and a trend towards savings. Secondly, hybrid systems enable the production of quality products with increased efficiency. By integrating various functions in one process equipment, metalworking processes become more efficient and precise. This reduces the amount of defective products and improves the quality of the final ones. In addition, hybrid metalworking systems have autonomous functionality, which is especially important in flexible engineering production, where rapid changeover and adaptation to various production tasks is required. Thus, hybrid metalworking systems represent an important step in the development of modern mechanical engineering, helping to reduce costs, increase efficiency and ensure high product quality. The purpose of this work is to increase efficiency and reduce energy consumption during surface-thermal hardening of machine parts through the use of concentrated energy sources under integral processing conditions. Theory and Methods. To achieve this purpose, studies were carried out on the possible structural composition and layout of hybrid equipment integrating mechanical and surface-thermal processes. When developing the theory and methods, the main provisions of the structural synthesis and components of metalworking systems were taken into account. Theoretical research is based on the application of system analysis, geometric theory of surface formation and design of metalworking machines. The experiments were carried out on a modernized multi-purpose machining center MS 032.06, equipped with an additional energy source, which was a microwave thyristor-type generator SHF-10 with an operating frequency of 440 kHz, which implements high-energy heating by high-frequency currents. Structural studies were carried out using optical and scanning microscopy. The stress-strain state of the surface layer of the part was evaluated by mechanical and X-ray methods for determining residual stresses. The microhardness of the hardened surface layer of the parts was evaluated on a Wolpert Group 402MVD instrument. Results and discussion. An original method for conducting structural-kinematic analysis for pre-project studies of hybrid metalworking equipment is presented. Methodological recommendations were developed for the modernization of metal-cutting machine tools, allowing high-energy heating with high-frequency currents (HEH HFC) on a standard machine tool system and creating high-tech technological equipment with enhanced functionality. It has been experimentally confirmed that the introduction of the proposed hybrid machine into production in combination with recommendations for the appointment of high-frequency elec
介绍。在机床工业中，混合金属加工系统集群的发展带来了许多积极的后果。首先，这种系统通过优化资源和能源的使用，有助于降低生产成本。面对日益激烈的竞争和储蓄趋势，这一点尤其正确。其次，混合系统能够以更高的效率生产高质量的产品。通过在一个工艺设备中集成各种功能，金属加工过程变得更加高效和精确。这减少了次品的数量，提高了最终产品的质量。此外，混合金属加工系统具有自主功能，这在需要快速转换和适应各种生产任务的柔性工程生产中尤为重要。因此，混合金属加工系统代表了现代机械工程发展的重要一步，有助于降低成本，提高效率并确保高产品质量。本工作的目的是通过在整体加工条件下使用集中的能量源，提高机械零件表面热硬化的效率，降低能耗。理论与方法。为了实现这一目的，对机械和表面热过程相结合的混合设备可能的结构组成和布局进行了研究。在发展理论和方法时，考虑到金属加工系统的结构综合和组成的主要规定。理论研究是基于系统分析、表面形成的几何理论和金属加工机械设计的应用。实验在现代化多用途加工中心MS 032.06上进行，该加工中心附加能量源为工作频率为440 kHz的微波晶闸管型发生器SHF-10，利用高频电流实现高能加热。使用光学显微镜和扫描显微镜进行结构研究。采用机械法和x射线法测定残余应力，评价了零件表层的应力-应变状态。采用Wolpert Group 402MVD仪对零件表面硬化层的显微硬度进行了测定。结果和讨论。提出了一种用于混合金属加工设备工程前期研究的结构-运动学分析方法。为金属切削机床的现代化制定了方法建议，允许在标准机床系统上使用高频电流(HEH HFC)进行高能加热，并创建具有增强功能的高科技技术设备。实验证实，将所提出的混合机床引入生产，并结合建议指定高频电力单元进行冲孔类零件的整体加工，可以将表面硬化生产率提高36-40倍，并将能源成本降低6倍。
{"title":"Rationalization of modes of HFC hardening of working surfaces of a plug in the conditions of hybrid processing","authors":"Vadim Skeeba, Nikita Vakhrushev, Kristina Titova, Aleksey Chernikov","doi":"10.17212/1994-6309-2023-25.3-63-86","DOIUrl":"https://doi.org/10.17212/1994-6309-2023-25.3-63-86","url":null,"abstract":"Introduction. The development of a cluster of hybrid metalworking systems in the machine tool industry is associated with a number of positive consequences. First, such systems help reduce production costs by optimizing the use of resources and energy. This is especially true in the face of increased competition and a trend towards savings. Secondly, hybrid systems enable the production of quality products with increased efficiency. By integrating various functions in one process equipment, metalworking processes become more efficient and precise. This reduces the amount of defective products and improves the quality of the final ones. In addition, hybrid metalworking systems have autonomous functionality, which is especially important in flexible engineering production, where rapid changeover and adaptation to various production tasks is required. Thus, hybrid metalworking systems represent an important step in the development of modern mechanical engineering, helping to reduce costs, increase efficiency and ensure high product quality. The purpose of this work is to increase efficiency and reduce energy consumption during surface-thermal hardening of machine parts through the use of concentrated energy sources under integral processing conditions. Theory and Methods. To achieve this purpose, studies were carried out on the possible structural composition and layout of hybrid equipment integrating mechanical and surface-thermal processes. When developing the theory and methods, the main provisions of the structural synthesis and components of metalworking systems were taken into account. Theoretical research is based on the application of system analysis, geometric theory of surface formation and design of metalworking machines. The experiments were carried out on a modernized multi-purpose machining center MS 032.06, equipped with an additional energy source, which was a microwave thyristor-type generator SHF-10 with an operating frequency of 440 kHz, which implements high-energy heating by high-frequency currents. Structural studies were carried out using optical and scanning microscopy. The stress-strain state of the surface layer of the part was evaluated by mechanical and X-ray methods for determining residual stresses. The microhardness of the hardened surface layer of the parts was evaluated on a Wolpert Group 402MVD instrument. Results and discussion. An original method for conducting structural-kinematic analysis for pre-project studies of hybrid metalworking equipment is presented. Methodological recommendations were developed for the modernization of metal-cutting machine tools, allowing high-energy heating with high-frequency currents (HEH HFC) on a standard machine tool system and creating high-tech technological equipment with enhanced functionality. It has been experimentally confirmed that the introduction of the proposed hybrid machine into production in combination with recommendations for the appointment of high-frequency elec","PeriodicalId":42889,"journal":{"name":"Obrabotka Metallov-Metal Working and Material Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-09-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135439630","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}
Pub Date : 2023-09-15DOI: 10.17212/1994-6309-2023-25.3-117-125
Savendra Singh, Chetan Hirwani
Introduction. With increasing environmental concern nowadays, researchers are studying new alternating materials that can meet the society needs and are extracted from renewable and biodegradable resources. The various natural fibers have been investigated by researchers to replace synthetic ones. The purpose of the work. In present study, treated saccharum munja fibers considered as reinforcement material in Particulate (PC), Short and Random (SRC) and in Unidirectional (UDC) form along with AW106 Resin and HV953. The paper assesses the mechanical properties of Munya fibers (Saccharum munja). Initial six natural frequencies along with corresponding damping factors are measured to analyze the possibility of using a composite material. Research methods. A compression molding machine was used to form laminated composite materials. Surface treatment of fibers removes the dust, lignin and hemicellulose, which improves mechanical and free vibration properties. Results and Discussion. Tensile and flexural test shows the highest value of strength 170 MPa and 143 MPa in case of UDC composite, and the lowest in the case of PC. Addition of munja fiber to epoxy matrix enhances the fiber matrix adhesion bonding. The PC composite shows better value of damping than SRC and UDC composite. The highest natural frequency 43, 233, 298, 849, 918 and 1,440 Hz obtained in case of UDC irrespective of all modes. The results of the free vibration analysis show that Saccharum Munja fiber composite may be used as structural material. Analysis of variance (ANOVA) shows that the experimental results output in case of tensile and flexural teste are significant.
{"title":"Analysis of mechanical behavior and free vibration characteristics of treated Saccharum munja fiber polymer composite","authors":"Savendra Singh, Chetan Hirwani","doi":"10.17212/1994-6309-2023-25.3-117-125","DOIUrl":"https://doi.org/10.17212/1994-6309-2023-25.3-117-125","url":null,"abstract":"Introduction. With increasing environmental concern nowadays, researchers are studying new alternating materials that can meet the society needs and are extracted from renewable and biodegradable resources. The various natural fibers have been investigated by researchers to replace synthetic ones. The purpose of the work. In present study, treated saccharum munja fibers considered as reinforcement material in Particulate (PC), Short and Random (SRC) and in Unidirectional (UDC) form along with AW106 Resin and HV953. The paper assesses the mechanical properties of Munya fibers (Saccharum munja). Initial six natural frequencies along with corresponding damping factors are measured to analyze the possibility of using a composite material. Research methods. A compression molding machine was used to form laminated composite materials. Surface treatment of fibers removes the dust, lignin and hemicellulose, which improves mechanical and free vibration properties. Results and Discussion. Tensile and flexural test shows the highest value of strength 170 MPa and 143 MPa in case of UDC composite, and the lowest in the case of PC. Addition of munja fiber to epoxy matrix enhances the fiber matrix adhesion bonding. The PC composite shows better value of damping than SRC and UDC composite. The highest natural frequency 43, 233, 298, 849, 918 and 1,440 Hz obtained in case of UDC irrespective of all modes. The results of the free vibration analysis show that Saccharum Munja fiber composite may be used as structural material. Analysis of variance (ANOVA) shows that the experimental results output in case of tensile and flexural teste are significant.","PeriodicalId":42889,"journal":{"name":"Obrabotka Metallov-Metal Working and Material Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-09-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135437696","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}
Pub Date : 2023-09-15DOI: 10.17212/1994-6309-2023-25.3-126-136
Gennady Pribytkov, Anton Baranovskiy, Victoria Korzhova, Irina Firsina, Vladimir Krivopalov
Introduction. Intermetallic compounds Fe2Ti and FeTi are of practical application as hydrogen accumulators (FeTi) or as magnetic materials (Fe2Ti). Due to the peculiarities of the double equilibrium diagram, the production of these intermetallic compounds by casting is difficult. Therefore, powder metallurgy methods are widely used combined with preliminary mechanical activation of the powder mixtures. The aim of the work is to investigate the possibility of obtaining single-phase compounds from powder mixtures of titanium and iron of target compositions. Research methods. Mechanically activated powder mixtures, products of combustion and subsequent annealing were studied by X-ray phase analysis, optical metallography, and scanning electron microscopy using elemental composition determination by energy-dispersive X-ray spectroscopy. Research methodology. Powder mixtures were mechanically activated for 20 minutes in an Activator 2S planetary ball mill with an intensity of 40 g and a ball/mixture ratio of 20. The mechanically activated mixtures were heated in a sealed reactor in argon media at an average rate of 85 C°/min. Results and discussion. At a temperature of about 500 °C, thermographs of thermocouples placed in a mechanically activated mixture showed a sharp rise (thermal explosion), indicating an exothermic reaction in the mixture. The rise for the 2Fe + Ti composition turned out to be more pronounced than that for the Fe + Ti composition. X-ray diffraction analysis showed that the main reaction product is the Fe2Ti compound for both mixtures. The predominant formation of Fe2Ti is explained by the greater negative enthalpy of Fe2Ti formation of compared to FeTi (−87.45 and −40.58 kcal/mol, respectively). Conclusion. High-temperature annealing of thermal explosion products did not make it possible to obtain single-phase target products. The content of secondary phases and unreacted reagents changed little after annealing. Based on the obtained results, it was concluded that the thermodynamic factor (the enthalpy of formation of the intermetallic compound) is the main one that determines the phase composition of the synthesis products in powder mixtures of titanium and iron.
{"title":"Synthesis of Ti–Fe intermetallic compounds from elemental powders mixtures","authors":"Gennady Pribytkov, Anton Baranovskiy, Victoria Korzhova, Irina Firsina, Vladimir Krivopalov","doi":"10.17212/1994-6309-2023-25.3-126-136","DOIUrl":"https://doi.org/10.17212/1994-6309-2023-25.3-126-136","url":null,"abstract":"Introduction. Intermetallic compounds Fe2Ti and FeTi are of practical application as hydrogen accumulators (FeTi) or as magnetic materials (Fe2Ti). Due to the peculiarities of the double equilibrium diagram, the production of these intermetallic compounds by casting is difficult. Therefore, powder metallurgy methods are widely used combined with preliminary mechanical activation of the powder mixtures. The aim of the work is to investigate the possibility of obtaining single-phase compounds from powder mixtures of titanium and iron of target compositions. Research methods. Mechanically activated powder mixtures, products of combustion and subsequent annealing were studied by X-ray phase analysis, optical metallography, and scanning electron microscopy using elemental composition determination by energy-dispersive X-ray spectroscopy. Research methodology. Powder mixtures were mechanically activated for 20 minutes in an Activator 2S planetary ball mill with an intensity of 40 g and a ball/mixture ratio of 20. The mechanically activated mixtures were heated in a sealed reactor in argon media at an average rate of 85 C°/min. Results and discussion. At a temperature of about 500 °C, thermographs of thermocouples placed in a mechanically activated mixture showed a sharp rise (thermal explosion), indicating an exothermic reaction in the mixture. The rise for the 2Fe + Ti composition turned out to be more pronounced than that for the Fe + Ti composition. X-ray diffraction analysis showed that the main reaction product is the Fe2Ti compound for both mixtures. The predominant formation of Fe2Ti is explained by the greater negative enthalpy of Fe2Ti formation of compared to FeTi (−87.45 and −40.58 kcal/mol, respectively). Conclusion. High-temperature annealing of thermal explosion products did not make it possible to obtain single-phase target products. The content of secondary phases and unreacted reagents changed little after annealing. Based on the obtained results, it was concluded that the thermodynamic factor (the enthalpy of formation of the intermetallic compound) is the main one that determines the phase composition of the synthesis products in powder mixtures of titanium and iron.","PeriodicalId":42889,"journal":{"name":"Obrabotka Metallov-Metal Working and Material Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-09-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135437824","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}
Pub Date : 2023-09-15DOI: 10.17212/1994-6309-2023-25.3-6-18
Denis Salikhyanov, Nikolay Michurov
Introduction. Over the past decades, laminated composites based on aluminum alloys have been increasingly used in the aerospace and automotive industries. Laminated composites are usually produced by accumulative roll bonding, which results in the metallurgical bonding of initially prepared sheets. Hence, the main task of accumulative roll bonding is to obtain a reliable bond between materials. However, at present, the process of joining similar or dissimilar materials by plastic deformation is still a poorly understood phenomenon. In this regard, in recent years, methods of finite element modeling of the processes of joining materials have begun to develop intensively. The purpose of the work is to establish a relationship between stress-strain state parameters and the formation of a stable bond between aluminum alloys of different compositions. To achieve this goal, the following tasks are formulated: 1. Simulation of the laminated composite “AMg3/D16/AMg3” rolling process using data corresponding to physical experiments carried out at the Institute of Engineering Science of the Ural Branch of the Russian Academy of Sciences; 2. Selection and analysis of the most important stress-strain state parameters of the laminated composite “AMg3/D16/AMg3” rolling process. Research methods. Process simulation system Deform-3D was chosen as the main research tool. Results and Discussion. An analysis of the coordinate grid distortion and velocity vectors of material flow of layers revealed that the deformation is distributed inhomogeneously in the cross section after rolling: the outer layers flow more intensively compared to the middle layer. The maximum scatter of strain intensity ei in the cross section, observed at a maximum reduction ratio of 75%, is 12%. This allows one to accept for analytical calculations in the first approximation the assumption of deformation uniformity. A relationship is established between the beginning of the formation of a bond between composite layers and the threshold expansion of the contact surface and normal pressure at the interlayer boundary. In the final part of the study, future directions for improving the approaches of simulation the laminated composites rolling processes are proposed.
{"title":"Simulation of the rolling process of a laminated composite AMg3/D16/AMg3","authors":"Denis Salikhyanov, Nikolay Michurov","doi":"10.17212/1994-6309-2023-25.3-6-18","DOIUrl":"https://doi.org/10.17212/1994-6309-2023-25.3-6-18","url":null,"abstract":"Introduction. Over the past decades, laminated composites based on aluminum alloys have been increasingly used in the aerospace and automotive industries. Laminated composites are usually produced by accumulative roll bonding, which results in the metallurgical bonding of initially prepared sheets. Hence, the main task of accumulative roll bonding is to obtain a reliable bond between materials. However, at present, the process of joining similar or dissimilar materials by plastic deformation is still a poorly understood phenomenon. In this regard, in recent years, methods of finite element modeling of the processes of joining materials have begun to develop intensively. The purpose of the work is to establish a relationship between stress-strain state parameters and the formation of a stable bond between aluminum alloys of different compositions. To achieve this goal, the following tasks are formulated: 1. Simulation of the laminated composite “AMg3/D16/AMg3” rolling process using data corresponding to physical experiments carried out at the Institute of Engineering Science of the Ural Branch of the Russian Academy of Sciences; 2. Selection and analysis of the most important stress-strain state parameters of the laminated composite “AMg3/D16/AMg3” rolling process. Research methods. Process simulation system Deform-3D was chosen as the main research tool. Results and Discussion. An analysis of the coordinate grid distortion and velocity vectors of material flow of layers revealed that the deformation is distributed inhomogeneously in the cross section after rolling: the outer layers flow more intensively compared to the middle layer. The maximum scatter of strain intensity ei in the cross section, observed at a maximum reduction ratio of 75%, is 12%. This allows one to accept for analytical calculations in the first approximation the assumption of deformation uniformity. A relationship is established between the beginning of the formation of a bond between composite layers and the threshold expansion of the contact surface and normal pressure at the interlayer boundary. In the final part of the study, future directions for improving the approaches of simulation the laminated composites rolling processes are proposed.","PeriodicalId":42889,"journal":{"name":"Obrabotka Metallov-Metal Working and Material Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-09-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135439629","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}
Introduction. The presses are powered machines having stationary beds and slides (rams) which have controlled sliding motion towards and away from the beds, guided by the frames. Metal can be worked in power press in a wide verity of ways like punching, shearing, forming, etc. Crankshaft is one of the basic components for power transmission, which transmits rotary motion to sliding motion in the mechanical power press. It is around this element that all stresses and deformations are concentrated. The purpose of the study: rationalization of the design of the crankshaft, taking into account the strength characteristics of the frame, connection screws, tie rods. The methods include two stages of crankshaft design development: 1) modelling in parametric cad software; 2) FE analysis in Ansys-22R1. The existing as well as the improved design of the crankshaft was investigated by the FE method with topology analysis. Topology is part of FE analysis as well as Generative design. Result and Discussion. The design of the crankshaft, including the bearing assembly, depends largely on the maximum pressure that will be generated at the bottom of the stroke, and this is carefully considered when designing other parts of the presses. Based on the results of the topology analysis of the crankshaft structure, it was found that an increase in the strength of this structural element is possible by adding additional material in the area of potential destruction. During the study, it was possible to develop a rational design of the crankshaft with improved mechanical properties compared to the existing one, which will increase the service life of the crankshaft, preventing its failure.
{"title":"Economical crankshaft design through topology analysis for C type gap frame power press SNX-320","authors":"Darshan Tratiya, Manojkumar Sheladiya, Ghanshyam Acharya, Shailee Acharya","doi":"10.17212/1994-6309-2023-25.3-50-62","DOIUrl":"https://doi.org/10.17212/1994-6309-2023-25.3-50-62","url":null,"abstract":"Introduction. The presses are powered machines having stationary beds and slides (rams) which have controlled sliding motion towards and away from the beds, guided by the frames. Metal can be worked in power press in a wide verity of ways like punching, shearing, forming, etc. Crankshaft is one of the basic components for power transmission, which transmits rotary motion to sliding motion in the mechanical power press. It is around this element that all stresses and deformations are concentrated. The purpose of the study: rationalization of the design of the crankshaft, taking into account the strength characteristics of the frame, connection screws, tie rods. The methods include two stages of crankshaft design development: 1) modelling in parametric cad software; 2) FE analysis in Ansys-22R1. The existing as well as the improved design of the crankshaft was investigated by the FE method with topology analysis. Topology is part of FE analysis as well as Generative design. Result and Discussion. The design of the crankshaft, including the bearing assembly, depends largely on the maximum pressure that will be generated at the bottom of the stroke, and this is carefully considered when designing other parts of the presses. Based on the results of the topology analysis of the crankshaft structure, it was found that an increase in the strength of this structural element is possible by adding additional material in the area of potential destruction. During the study, it was possible to develop a rational design of the crankshaft with improved mechanical properties compared to the existing one, which will increase the service life of the crankshaft, preventing its failure.","PeriodicalId":42889,"journal":{"name":"Obrabotka Metallov-Metal Working and Material Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-09-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135439631","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}
京公网安备 11010802042870号
京ICP备2023020795号-1
扫码关注我们
求助内容：
应助结果提醒方式：