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Simulation of the relationship between input factors and output indicators of the internal grinding process, considering the mutual vibrations of the tool and the workpiece 考虑刀具与工件相互振动的内磨过程输入因素与输出指标之间关系的仿真
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2023-03-15 DOI: 10.17212/1994-6309-2023-25.1-57-70
S. Bratan, A. Chasovitina
Introduction. In real production conditions, the technological modes recommended in the scientific literature do not reflect the declared qualities, due to the fact that it does not take into account many factors inherent in the process of finishing grinding, for example, its stochastic nature, changes in its dynamic properties, an increase in mutual vibrations of the tool and the workpiece that appear due to changes in the state of the technological system, for example, an increase in vibrations machine tool due to uneven tool wear, etc. All previously developed models have a limited scope of application, it does not take into account the fact that the appearance of vibrations leads to fluctuations in the depth of grinding, with accidental contact of grains with the material being processed, where one group of grains cuts off the material, the other gets into the trace of scratches left by previous grains, etc. This leads to changes in the values of material removal, surface roughness and other parameters of the technological system, which directly affects the accuracy of processing and the quality of the machined surfaces. The purpose of the work is to develop mathematical models that establish the relationship between the processing modes and the current parameters of the contact zone during the fine grinding of pinholes, taking into account the mutual vibrations of the tool and the workpiece. The research methods are mathematical simulation using the basic provisions of the theory of abrasive-diamond processing. Results and discussion. The interrelations between the cutting modes and the current input parameters of the contact zone when grinding pinholes are established, taking into account the mutual vibrations of the tool and the workpiece, which make it possible to determine the parameters of the system at the output to avoid cost losses, including reducing the number of defective products and time costs. Non-stationary mathematical dependences are constructed that allow determining the cutting modes during the implementation of the grinding cycle, taking into account the magnitude of relative vibrations and the initial phase. It is established that instead of a steady process, harmonic oscillations are observed caused by deviations in the shape of the circle, the intensity of tool wear and other factors, all of the above has a significant impact on the quality of the machined surface. The obtained models are universal for various characteristics of the tool, however, for a more adequate description of the process, mathematical dependencies are needed that take into account the wear of the tool on various binders, which is the task of further research.
介绍在实际生产条件下,科学文献中推荐的技术模式并没有反映所宣称的质量,因为它没有考虑精磨过程中固有的许多因素,例如其随机性、动态特性的变化、,由于技术系统状态的变化而出现的工具和工件的相互振动的增加,例如,由于不均匀的工具磨损而导致的机床振动的增加等。所有先前开发的模型的应用范围都有限,它没有考虑到这样一个事实,即振动的出现会导致研磨深度的波动,晶粒与被加工材料的意外接触,其中一组晶粒切断了材料,另一组晶粒进入了先前晶粒留下的划痕痕迹,等等。这会导致材料去除值的变化,表面粗糙度等工艺系统参数,直接影响加工精度和加工表面质量。这项工作的目的是开发数学模型,在考虑工具和工件的相互振动的情况下,建立针孔精磨过程中接触区的加工模式和当前参数之间的关系。研究方法是利用数学模拟的基本规定对金刚石磨料进行加工。结果和讨论。在考虑到工具和工件的相互振动的情况下,建立了磨削针孔时切削模式和接触区的当前输入参数之间的相互关系,这使得可以在输出端确定系统的参数,以避免成本损失,包括减少缺陷产品的数量和时间成本。构建了非平稳数学依赖关系,允许在研磨周期的实施过程中确定切割模式,同时考虑相对振动的大小和初始阶段。已经确定,观察到的不是稳定的过程,而是由圆的形状偏差、刀具磨损强度和其他因素引起的谐波振荡,所有这些都对加工表面的质量有重大影响。所获得的模型对于工具的各种特性是通用的,然而,为了更充分地描述过程,需要考虑工具在各种粘合剂上的磨损的数学依赖性,这是进一步研究的任务。
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引用次数: 0
Diffusion coatings formation features, obtained by complex chemical-thermal treatment on the structural steels 通过对结构钢进行复合化学热处理,获得扩散涂层的形成特征
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2023-03-15 DOI: 10.17212/1994-6309-2023-25.1-98-109
A. Sokolov, E. Bobylyov, R. Popov
Introduction. The main methods of increasing the efficiency of products made from structural steels are considered. A description of diffusion saturation from liquid metal media solutions (DSLMMS) is given. Also, complex diffusion saturation technology (CDS), including DSLMMS and carburization is shown. The purpose of the work is to reveal the effect of steel composition on the process of formation and elemental composition of diffusion-saturated surface layers (coatings) based on chromium, as well as to establish differences and regularities in the processes of formation of diffusion-saturated coatings after DSLMMS and CDS. The methods of investigation. Cylindrical specimens 20 mm in diameter and 30 mm long were subjected to DSLMMS. The specimens were made of carbon and alloyed steels: St3, 20-Cr13, 40-Cr, 40-Cr13, 12-Cr18-Ni10-Ti. At the same time, some of the specimens were previously subjected to vacuum cementation. An eutectic Pb-Bi with the specified content of Cr was used as a transport medium when executing DSLMMS. Metallographic studies were carried out on microsection prepared according to the standard method. Studies to determine the thickness of coatings and its structure were carried out on the Dura Scan Falcon 500 Microhardness Tester. The elemental composition of the coatings was determined by the method of electron microprobe analysis on a Tescan Lyra 3 scanning electron microscope with the Oxford Ultim MAX PCMA system. Results and discussion. As a result of the research, it was revealed that the formation of saturated coatings occurs with DSLMMS and CDS. At the same time, the thickness of the coatings and its elemental composition depend on the steel grade and the technology used. After DSLMMS concentration of Cr varies from 96.9% to 91.1%. At the same time, the maximum concentration of 96.9% is observed on steel St3. After CDS, on the surfaces of all steel samples, the concentration of Cr decreases in comparison with the coatings obtained by the DSLMMS technology on steels: St3 from 96.9% to 66.8%; 40-Cr from 91.1% to 63.18%; 20-Cr13 from 93.18% to 62.54%; 12-Cr18-Ni10-Ti from 92.92% to 64.77%. The total thickness of diffusion-saturated coatings formed on all the alloys studied ranges from 17 to 17.5 µm.
介绍考虑了提高结构钢产品效率的主要方法。给出了液态金属介质溶液扩散饱和的描述。此外,还介绍了复合扩散饱和技术(CDS),包括DSLMMS和渗碳。本工作的目的是揭示钢成分对基于铬的扩散饱和表面层(涂层)形成过程和元素组成的影响,以及建立DSLMMS和CDS后扩散饱和涂层形成过程的差异和规律。调查方法。对直径为20mm、长度为30mm的圆柱形试样进行DSLMMS。试样由碳钢和合金钢制成:St3、20-Cr13、40Cr、40-Cr13、12-Cr18-Ni10-Ti。同时,一些试样之前进行了真空胶结。在执行DSLMMS时,使用具有特定Cr含量的共晶Pb-Bi作为传输介质。对根据标准方法制备的显微切片进行了金相研究。在Dura Scan Falcon 500显微硬度计上进行了测定涂层厚度及其结构的研究。涂层的元素组成通过电子探针分析方法在具有Oxford Ultim MAX PCMA系统的Tescan Lyra 3扫描电子显微镜上测定。结果和讨论。研究结果表明,DSLMMS和CDS会形成饱和涂层。同时,涂层的厚度及其元素组成取决于钢的等级和所使用的技术。DSLMMS后Cr的浓度在96.9%~91.1%之间变化,同时在St3钢上观察到最大浓度为96.9%。CDS后,在所有钢样品的表面上,与DSLMMS技术在钢上获得的涂层相比,Cr的浓度降低:St3从96.9%降低到66.8%;40Cr从91.1%提高到63.18%;20-Cr13从93.18%提高到62.54%;12-Cr18-Ni10-Ti从92.92%到64.77%。在所有研究的合金上形成的扩散饱和涂层的总厚度范围为17到17.5µm。
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引用次数: 0
The effect of borocoppering duration on the composition, microstructure and microhardness of the surface of carbon and alloy steels 硼铜化时间对碳钢和合金钢表面成分、显微组织和显微硬度的影响
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2023-03-15 DOI: 10.17212/1994-6309-2023-25.1-131-148
S. Lysykh, V. Kornopoltsev, U. Mishigdorzhiyn, Yu. P. Kharaev, A. Tikhonov, V. Ivancivsky, N. Vakhrushev
Introduction. Borocoppering is one of the methods of thermochemical treatment (TCT) aimed at forming diffusion layers with high physical and mechanical properties on the surface of carbon and alloy steels. The thickness of the diffusion layer is the most important characteristic of the TCT, which determines the depth of hardening. Consequently, the intensity and main characteristics of the TCT (layer thickness, alloying element concentration profile) depend on the process conditions (temperature, duration, and amount of alloying element). The purpose of this work is to determine the temperature-time parameters of diffusion borocoppering, which contribute to the formation of diffusion layers with a maximum thickness. The paper considers the results of surface hardening of carbon and alloy steels (for example, Steel 45 (0.45% C), Steel U10 (1.0% C), and 0.5C-Cr-Ni-Mn steel) by high-temperature soaking in powder mixtures containing boron and copper. Borocoppering was carried out in sealed containers with the powder mixture consisting of boron carbide, copper oxide, and sodium fluoride as an activator at a temperature of 950 °C for 3–5 h. The resulting specimens with a diffusion layer were examined using an optical microscope and a scanning electron microscope (SEM); the microhardness, elemental and phase composition of the layers were also determined, as well as the roughness of the obtained surfaces. Results and discussions. The microstructure of the obtained diffusion layers is studied; diagrams of the changes in the layers’ thickness and the microhardness distribution over the layers’ thickness are shown. It is established that with an increase in the soaking time from 3 to 5 h, the thickness of the diffusion layer increases from 120 to 170 μm on Steel 45 (0.45% C); from 110 to 155 µm on Steel U10 (1.0% C) and from 130 to 230 µm on 0.5C-Cr-Ni-Mn steel. A gradual decrease in the concentration of boron and copper along the layer thickness from 15–16% and 2–3% on the surface, respectively, to zero values at the boundary with the base metal is revealed. It is established that borocoppering to the formation of more thick boride layers on the surface of carbon and alloy steels compared to pure boriding. Moreover, an increase in the duration of soaking during the process contributes to the greatest increase in the thickness of the layer on 0.5C-Cr-Ni-Mn steel. A study of microgeometry is carried out, microtopographies and profilograms of specimens’ surfaces are shown before and after borocoppering. It is established that the roughness after borocoppering increases by 2-3 times compared to the initial one, and an increase in the duration of the process does not have a significant effect on the roughness.
介绍。硼铜处理是在碳钢和合金钢表面形成具有高物理力学性能的扩散层的热化学处理方法之一。扩散层的厚度是TCT最重要的特性,它决定了硬化的深度。因此,TCT的强度和主要特征(层厚、合金元素浓度分布)取决于工艺条件(温度、持续时间和合金元素的量)。本工作的目的是确定扩散硼铜的温度-时间参数,该参数有助于形成最大厚度的扩散层。本文考虑了碳素钢和合金钢(例如45钢(0.45% C)、U10钢(1.0% C)和0.5C-Cr-Ni-Mn钢)在含硼和铜的粉末混合物中高温浸泡的表面硬化结果。用碳化硼、氧化铜和氟化钠作为活化剂的粉末混合物在密封容器中进行硼铜铜处理,温度为950℃,时间为3-5小时。用光学显微镜和扫描电子显微镜(SEM)检查有扩散层的样品;测定了各层的显微硬度、元素组成和相组成以及所得表面的粗糙度。结果和讨论。研究了扩散层的微观结构;图中显示了层厚度的变化和层厚度上的显微硬度分布。结果表明:随着保温时间从3 h增加到5 h, 45钢(0.45% C)的扩散层厚度从120 μm增加到170 μm;在U10钢(1.0% C)上从110到155微米,在0.5C-Cr-Ni-Mn钢上从130到230微米。硼和铜的浓度沿层厚逐渐下降,分别从表面的15-16%和2-3%降至与母材交界处的零值。与纯渗硼相比,硼铜化能在碳钢和合金钢表面形成更厚的硼化物层。同时,随着浸泡时间的增加,0.5C-Cr-Ni-Mn钢的层厚增加幅度最大。进行了微观几何的研究,显示了硼铜处理前后试样表面的微观形貌和轮廓图。结果表明,硼铜处理后的粗糙度比初始粗糙度提高了2-3倍,且处理时间的增加对粗糙度的影响不显著。
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引用次数: 0
Experimental study of the dynamics of the machining process by ball-end mills 球头立铣刀加工过程动力学的实验研究
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2023-03-15 DOI: 10.17212/1994-6309-2023-25.1-44-56
M. Gimadeev, A. Li, V. Berkun, V. Stelmakov
Introduction. Due to a significant number of factors affecting the change in the properties of a dynamic system, excessively conservative processing conditions are chosen to ensure the high quality of the resulting product. This limits the efficiency of the process and leads to an increase in the cost of production. Accordingly, modern approaches are needed that will allow diagnosing the current state of processing and making timely decisions to replace the tool, correct or change the control program. The significance of the ongoing research is to propose a real-time monitoring approach to milling control to identify emerging processing errors, predict potential problems and improve uptime. Subject. The paper discusses the features of the real-time monitoring system during mechanical processing with a single- and double-edge cutting tool, taking into account acoustic wave filtering, minimizing surface roughness. The purpose of the work is to determine the effect of the inclination orientation of the ball-end tool on the surface roughness value using real-time monitoring during milling on CNC process equipment. Methods. The study provides methods of correlation and regression analysis. The calculated data were obtained by means of vibroacoustic diagnostics and measured in the range of values of the variable angle of inclination of the surface for single- and double-edge cutting tool based on the provisions of the theory of oscillations and vibroacoustic diagnostics, cutting theory, digital processing and digital filtering of signals. Results and discussions. Experimental data obtained during machining made it possible to determine that an increase in the angle of inclination of a single-edge cutting tool has practically no effect on the change in the amplitude parameters of roughness. The values of vibroacoustic diagnostics and roughness, when using a double-edge ball-end tool, show a consistent picture with the effects created by the angles of inclination and advance. The obtained solutions to the problems of monitoring and analyzing the roughness parameters can significantly reduce the amount of experimental research and clarify the idea of the practical implementation of the method of acoustic monitoring of the cutting process.
介绍由于影响动态系统性能变化的因素很多,因此选择了过于保守的加工条件来确保最终产品的高质量。这限制了工艺的效率并导致生产成本的增加。因此,需要能够诊断当前处理状态并及时做出更换工具、纠正或更改控制程序的决定的现代方法。正在进行的研究的意义在于提出一种实时监控铣削控制的方法,以识别新出现的加工错误,预测潜在问题并提高正常运行时间。主题本文讨论了单刃和双刃切削刀具机械加工过程中实时监测系统的特点,该系统考虑了声波滤波,最大限度地减少了表面粗糙度。本工作的目的是通过在数控加工设备上进行铣削过程中的实时监测,确定球头刀具的倾斜方向对表面粗糙度值的影响。方法。该研究提供了相关和回归分析的方法。根据振荡和振动声诊断理论、切削理论、信号的数字处理和数字滤波的规定,通过振动声诊断获得计算数据,并在单刃和双刃切削刀具表面可变倾角的值范围内进行测量。结果和讨论。在机械加工过程中获得的实验数据使得可以确定,单刃切削工具的倾斜角度的增加实际上对粗糙度的振幅参数的变化没有影响。当使用双边球端工具时,振动声学诊断和粗糙度的值显示出与倾斜角和前进角产生的影响一致的图像。所获得的粗糙度参数监测和分析问题的解决方案可以显著减少实验研究的数量,并阐明切削过程声学监测方法的实际实施思路。
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引用次数: 1
Synthesis of the drive mechanism of the continuous production machine 连续生产机传动机构的综合
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2023-03-15 DOI: 10.17212/1994-6309-2023-25.1-71-84
Yuriy Podgornyj, A. Kirillov, V Yu Skeeba, T. Martynova, D. Lobanov, N. Martyushev
Introduction. Existing mixing devices operate at a constant angular velocity of the working body. During this process, there are zones in which there may be no movement of material, which leads to a decrease in the quality of the finished product. When the working body moves with a variable angular rate, the inertia forces, when changing its sign, contribute to the creation of conditions under which the mixture will lose contact with the blade and move to new levels of movement, and this helps to improve the quality and intensity of the mixing process. The purpose of the work is to improve the quality of the processed mixture on horizontal blade (kneading) machine. Methods. Theoretical studies are carried out using the basic provisions of the theory of machines and mechanisms, structural and parametric synthesis, kinematic analysis, mathematical and computer simulation. Results and discussion. In accordance with the proposed method, the synthesis of the cam-rocker mechanism is carried out, which made it possible to select the main dimensions for the cam mechanism: the minimum radius and center distance. For the synthesis of the rocker group, the parameters of the synthesized cam mechanism are used and, using the main parameters for the rocker group (the size of the input link, the angle of the second arm initial position and rocker centre line, equal to 90°). The rocker arm span angle is obtained equal to 103°. As a result of the kinematic calculation, it is found that the dwell time of the working shafts is within 80°. The quality of the mixture can be assessed by the angle of the stagnation zone, which is formed during the movement of granular material. Under static conditions, it is equal to 0.846°, and at variable angular rate — 0.550°. It is theoretically confirmed that inertial forces that change sign four times in one cycle will provide shaking and rebound of the mixed mass from the blades, which, in turn, will significantly improve the quality of the mixture.
介绍现有的混合装置在工作体的恒定角速度下操作。在这个过程中,有一些区域可能没有材料移动,这会导致成品质量下降。当工作体以可变角速率移动时,惯性力在改变其符号时,有助于创造条件,在这种条件下,混合物将失去与叶片的接触,并移动到新的移动水平,这有助于提高混合过程的质量和强度。这项工作的目的是提高在卧式叶片(捏合)机上加工的混合物的质量。方法。理论研究是利用机器和机构理论、结构和参数综合、运动学分析、数学和计算机模拟的基本规定进行的。结果和讨论。根据所提出的方法,对凸轮摇杆机构进行了综合,从而可以选择凸轮机构的主要尺寸:最小半径和中心距。对于摇杆组的合成,使用合成凸轮机构的参数,并使用摇杆组的主要参数(输入连杆的尺寸、第二个臂初始位置和摇杆中心线的角度,等于90°)。摇臂跨度角等于103°。运动学计算结果表明,工作轴的停留时间在80°以内。混合物的质量可以通过颗粒材料运动过程中形成的停滞区的角度来评估。在静态条件下,它等于0.846°,在可变角速度下——0.550°。理论上证实,在一个循环中四次改变符号的惯性力将提供混合质量从叶片的抖动和反弹,这反过来将显著提高混合物的质量。
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引用次数: 1
Analysis of the reasons for the formation of defects in the 12-Cr18-Ni10-Ti steel billets and development of recommendations for its elimination 12-Cr18-Ni10-Ti钢坯缺陷形成原因分析及消除建议
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2023-03-15 DOI: 10.17212/1994-6309-2023-25.1-6-15
S. Ryaboshuk, P. Kovalev
Introdution. Austenitic steel (e.g., AISI 304, AISI 321, AISI 316, AISI 403, 12-Cr18-Ni10-Ti, etc.) is widespread, which is caused by high corrosion resistance and the corresponding possibility of use in aggressive media. The following most common types of 12-Cr18-Ni10-Ti steel defects can be distinguished: integranular corrosion, martensitic orientation of the α-phase and ferrite δ-phase. The purpose of work: to analyze the defects formation reasons of the 12-Cr18-Ni10-Ti steel grade billets and to develop recommendations for their elimination. The methods of investigation. Tests of 12-Cr18-Ni10-Ti steel samples for resistance to integranular corrosion, metallographic analysis of defects were carried out in this work. Hardness measurements were carried out for various degrees of billets reduction. Thermodynamic calculations of phase equilibrium in multicomponent steel for different temperatures were performed by the Thermo-Calc software. Results and Discussion. It is determined that in order to prevent integranular corrosion, it is necessary to reduce the nitrogen and carbon content in steel at the stage of ladle refining to 0.05%, and also to ensure the concentration of titanium in steel is not less than the permissible value — 0.3%. These measures contribute to the reduction of Cr23C6 chromium carbides responsible for integranular corrosion. It is necessary to reduce the degree of compression of the billets to a level of no more than 50% to prevent the appearance of a ferromagnetic martensitic α-phase, since the formation of this defect is associated with a high degree of compression during drawing. The high-temperature phase of δ-ferrite exists in the metal structure in a wide temperature range. Reducing this range to 100 degrees or less by optimizing the composition of the carbon and chromium alloy in accordance with GOST 5632-2014 leads to a significant reduction of the amount of ferrite. However, it is not possible to completely eliminate it from the structure of steel. For all cases, it is necessary to assign austenization of billets in the temperature range of 1,050…1,100 °C.
简介。奥氏体钢(例如AISI 304、AISI 321、AISI 316、AISI 403、12-Cr18-Ni10-Ti等)广泛使用,这是由于高耐腐蚀性和在腐蚀性介质中使用的相应可能性造成的。12-Cr18-Ni10-Ti钢最常见的缺陷类型可分为:整体腐蚀、α相和铁素体δ相的马氏体取向。工作目的:分析12-Cr18-Ni10-Ti钢级钢坯缺陷形成的原因,并提出消除缺陷的建议。调查方法。本文对12-Cr18-Ni10-Ti钢试样进行了抗整体腐蚀试验,并对缺陷进行了金相分析。对不同程度的坯料还原度进行了硬度测量。使用Thermo-Calc软件对不同温度下多组分钢的相平衡进行了热力学计算。结果和讨论。确定为防止整体晶粒腐蚀,必须在钢包精炼阶段将钢中的氮和碳含量降低到0.05%,并确保钢中钛的浓度不低于允许值0.3%。这些措施有助于减少导致整体晶粒腐蚀的Cr23C6铬碳化物。有必要将坯料的压缩程度降低到不超过50%的水平,以防止出现铁磁马氏体α相,因为这种缺陷的形成与拉伸过程中的高度压缩有关。δ-铁氧体的高温相存在于金属结构中,温度范围很宽。根据GOST 5632-2014,通过优化碳和铬合金的成分,将该范围降低到100度或更低,可显著减少铁素体的量。然而,不可能将其从钢结构中完全消除。在所有情况下,有必要在1050…1100°C的温度范围内对钢坯进行奥氏体化。
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引用次数: 0
Determination of the optimal metal processing mode when analyzing the dynamics of cutting control systems 在分析切削控制系统的动力学时,确定最优的金属加工方式
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2023-03-15 DOI: 10.17212/1994-6309-2023-25.1-16-43
Victor Lapshin, D. Moiseev
Introduction. In numerous experimental studies of metal cutting processes on metal-cutting equipment, the existence of some optimal processing mode is noted, which was most vividly formulated by A.D. Makarov in his point on the existence of an optimal cutting temperature (processing speed). Here, by the authors from Russia, the emphasis is on the description of the optimality of cutting processes related to the properties of the processed material and the properties of the tool used in this process. However, there is another opinion in the Western scientific literature, which is generally based on the regenerative nature of vibrations in cutting dynamics. Vibration regeneration is associated with the dynamics of the cutting process, which is significantly affected by a lagging argument reflecting the variability of the cut layer. The connection of these two approaches is seen through the analysis of the stability domain of the dynamic cutting system in the parameter space: cutting speeds and tool wear values. Subject. Based on this, the paper considers the question of the relationship between the optimal according to A.D. Makarov the processing mode and the dynamics of the cutting process, including the regeneration of tool vibrations during metal turning. To do this, two research hypotheses are formulated and numerical modeling is performed in order to determine its reliability. Purpose of the work: to consider the position of A.D. Makarov on the existence of an optimal cutting mode, from the point of view of the stability of the dynamics of metal turning. For this purpose, two hypotheses are put forward in the work to be analyzed. The paper investigates: a mathematical model describing the dynamics of vibration oscillations of the cutting wedge tip, taking into account the dynamics of the temperature formed in the contact zone and its influence on the forces that prevent the forming motions of the tool. Research methods: a series of field experiments was carried out on a metalworking equipment using the capabilities of the measuring stand STD.201-1, the purpose of which was to determine the effect of the thermal expansion of metals on the value of the buoyant force. Based on numerical simulation of the initial nonlinear mathematical models, as well as simulation of models linearized in the vicinity of the equilibrium point, an analysis of the stability of the cutting system with variations in the cutting speed and the amount of tool wear along the flank is conducted. The results of the work. The results of field experiments are presented, which showed a significant linear increase in the force pushing out the tool with an increase in temperature in the contact zone of the tool and the workpiece. The results of simulation of the state and the corresponding phase trajectories when the cutting wedge is embedded in the workpiece, as well as the forces decomposed along the axis of deformation of the tool, are presented. The results of modeling the M
介绍。在对金属切削设备上的金属切削过程进行的大量实验研究中,都注意到存在某种最优加工方式,ad . Makarov最形象地阐述了最优切削温度(加工速度)的存在。在这里,来自俄罗斯的作者强调的是与加工材料的性能和在此过程中使用的工具的性能相关的切削过程的最佳性的描述。然而,在西方科学文献中有另一种观点,这种观点通常基于切削动力学中振动的再生性质。振动再生与切削过程的动力学有关,切削过程受到反映切削层可变性的滞后参数的显著影响。通过在切削速度和刀具磨损值参数空间中分析动态切削系统的稳定域,可以看出这两种方法之间的联系。主题。在此基础上,本文考虑了ad . Makarov最优加工模式与切削过程动力学之间的关系问题,包括金属车削过程中刀具振动的再生。为此,提出了两个研究假设,并进行了数值模拟,以确定其可靠性。工作目的:从金属车削动力学稳定性的角度,考虑ad . Makarov位置上存在的一种最优切削模式。为此,在待分析的工作中提出了两个假设。本文研究了一个描述切削楔尖振动振荡动力学的数学模型,该模型考虑了接触区形成的温度动力学及其对阻止刀具形成运动的力的影响。研究方法:利用STD.201-1测量台的能力,在金属加工设备上进行了一系列的现场实验,目的是确定金属热膨胀对浮力值的影响。基于初始非线性数学模型的数值模拟和平衡点附近线性化模型的仿真,分析了切削速度和刀具沿刀面磨损量随切削系统稳定性的变化。工作的结果。现场实验结果表明,随着刀具与工件接触区温度的升高,刀具的推力呈显著的线性增加。给出了切削楔嵌入工件时的状态和相轨迹的仿真结果,以及沿刀具变形轴方向分解的力。给出了切削过程动力学线性化模型的米哈伊洛夫矢量图建模结果。结论:研究结果表明,只有作者提出的第二个假设才有可能充分解释A.D. Makarov提出的观点。除了对ad . Makarov观点的描述之外,作者认为有必要考虑随着刀具和工件接触区温度的升高而产生的推力变化。
{"title":"Determination of the optimal metal processing mode when analyzing the dynamics of cutting control systems","authors":"Victor Lapshin, D. Moiseev","doi":"10.17212/1994-6309-2023-25.1-16-43","DOIUrl":"https://doi.org/10.17212/1994-6309-2023-25.1-16-43","url":null,"abstract":"Introduction. In numerous experimental studies of metal cutting processes on metal-cutting equipment, the existence of some optimal processing mode is noted, which was most vividly formulated by A.D. Makarov in his point on the existence of an optimal cutting temperature (processing speed). Here, by the authors from Russia, the emphasis is on the description of the optimality of cutting processes related to the properties of the processed material and the properties of the tool used in this process. However, there is another opinion in the Western scientific literature, which is generally based on the regenerative nature of vibrations in cutting dynamics. Vibration regeneration is associated with the dynamics of the cutting process, which is significantly affected by a lagging argument reflecting the variability of the cut layer. The connection of these two approaches is seen through the analysis of the stability domain of the dynamic cutting system in the parameter space: cutting speeds and tool wear values. Subject. Based on this, the paper considers the question of the relationship between the optimal according to A.D. Makarov the processing mode and the dynamics of the cutting process, including the regeneration of tool vibrations during metal turning. To do this, two research hypotheses are formulated and numerical modeling is performed in order to determine its reliability. Purpose of the work: to consider the position of A.D. Makarov on the existence of an optimal cutting mode, from the point of view of the stability of the dynamics of metal turning. For this purpose, two hypotheses are put forward in the work to be analyzed. The paper investigates: a mathematical model describing the dynamics of vibration oscillations of the cutting wedge tip, taking into account the dynamics of the temperature formed in the contact zone and its influence on the forces that prevent the forming motions of the tool. Research methods: a series of field experiments was carried out on a metalworking equipment using the capabilities of the measuring stand STD.201-1, the purpose of which was to determine the effect of the thermal expansion of metals on the value of the buoyant force. Based on numerical simulation of the initial nonlinear mathematical models, as well as simulation of models linearized in the vicinity of the equilibrium point, an analysis of the stability of the cutting system with variations in the cutting speed and the amount of tool wear along the flank is conducted. The results of the work. The results of field experiments are presented, which showed a significant linear increase in the force pushing out the tool with an increase in temperature in the contact zone of the tool and the workpiece. The results of simulation of the state and the corresponding phase trajectories when the cutting wedge is embedded in the workpiece, as well as the forces decomposed along the axis of deformation of the tool, are presented. The results of modeling the M","PeriodicalId":42889,"journal":{"name":"Obrabotka Metallov-Metal Working and Material Science","volume":" ","pages":""},"PeriodicalIF":0.4,"publicationDate":"2023-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45771026","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}
引用次数: 0
Development of plasma cutting technique for C1220 copper, AA2024 aluminum alloy, and Ti-1,5Al-1,0Mn titanium alloy using a plasma torch with reverse polarity 发展了用反极性等离子炬等离子切割C1220铜、AA2024铝合金和ti - 1,5al - 1,0mn钛合金的技术
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2022-12-15 DOI: 10.17212/1994-6309-2022-24.4-33-52
V. Rubtsov, A. Panfilov, E. Knyazhev, Aleksandra Nikolaeva, A. Cheremnov, A. Gusarova, V. Beloborodov, A. Chumaevskii, A. Ivanov
Introduction. An important area of research in the field of plasma metal cutting is obtaining a metal cut face characterized by minimal roughness and geometric deviations. It is also important to minimize changes in the structure of the metal under the cutting surface caused by the temperature effects of the plasma jet, including the formation of dross. The solution to the problem of obtaining a quality cut is to optimize the parameters of the cutting process. The plasma arc current and voltage, cutting height and cutting speed are considered to be the main parameters that determine cut quality. However, insufficient attention has been paid to the processes of plasma metal cutting of thicknesses above 20 mm due to the limitations associated with the operation conditions of plasma torches with direct polarity currents. Accordingly, for cutting large thicknesses, the use of a plasma torch operating on currents of reverse polarity seems promising. The aim of this work is to develop the technique of plasma cutting of copper, titanium and aluminum alloy sheets up to 40 mm thick using a plasma torch operating on currents of reverse polarity. Results and discussion. Investigations show that for cutting aluminum alloy (Al 90.9–94.7 %; Cu 3.8–4.9 %; Mg 1.2-1.8 %; Mn 0.3–0.9 %) and titanium alloy (Ti 94.33–97.5 %; Al 1.5–2.5 %; Mn 0.7–2.0 %) it is possible to regulate the cutting speed in a wide range, while for rolled copper (Cu ≥99.96 %) and aluminum alloy with thickness of 40 mm the range of cutting speed regulation is rather narrow. While for aluminum alloy due to excessive precipitation of alloying elements from the solid solution in the heat-affected zone decrease of microhardness is observed, for titanium alloy the microhardness growth due to material hardening is characteristic. Changing the cutting mode parameters allows receiving more homogeneous macrogeometry of a cutting surface, smaller depth of a zone of melting of a material and a heat-affected zone and smaller changes of mechanical properties of a material in a zone of a cut. For the titanium alloy, almost all of the cutting modes used are close to optimum. For alloy aluminum and copper the modes providing the best cutting quality in the considered range of parameters are determined. According to the results of the work it can be concluded that plasma cutting on reverse polarity currents is effective for cutting rolled products of large thicknesses, but the technique requires further development in order to improve the quality of the resulting cut.
介绍等离子体金属切削领域的一个重要研究领域是获得具有最小粗糙度和几何偏差的金属切削面。同样重要的是,尽量减少由等离子体射流的温度效应引起的切割表面下金属结构的变化,包括浮渣的形成。获得高质量切割的问题的解决方案是优化切割过程的参数。等离子弧电流和电压、切割高度和切割速度被认为是决定切割质量的主要参数。然而,由于与具有直接极性电流的等离子体炬的操作条件相关的限制,对厚度大于20mm的等离子体金属切割工艺没有给予足够的关注。因此,对于切割大厚度,使用在相反极性的电流下操作的等离子体炬似乎是有希望的。这项工作的目的是开发使用在反极性电流下操作的等离子体炬对厚度达40mm的铜、钛和铝合金板进行等离子体切割的技术。结果和讨论。研究表明,对于铝合金(Al 90.9–94.7%;Cu 3.8–4.9%;Mg 1.2-1.8%;Mn 0.3–0.9%)和钛合金(Ti 94.33–97.5%;Al 1.5–2.5%;Mn 0.7–2.0%)的切削,可以在较宽的范围内调节切削速度,而对于轧制铜(Cu≥99.96%)和厚度为40mm的铝合金,切削速度调节范围相当窄。对于铝合金,由于合金元素从热影响区的固溶体中过量沉淀,观察到显微硬度下降,而对于钛合金,由于材料硬化,显微硬度增长是其特征。改变切割模式参数允许接收更均匀的切割表面宏观几何形状、更小的材料熔化区和热影响区的深度以及更小的材料在切割区中的机械性能变化。对于钛合金,几乎所有使用的切割模式都接近最佳。对于合金铝和铜,确定了在所考虑的参数范围内提供最佳切割质量的模式。根据工作结果,可以得出结论,反向极性电流下的等离子体切割对于切割大厚度的轧制产品是有效的,但该技术需要进一步发展,以提高最终切割的质量。
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引用次数: 3
Studies of wear resistance and antifriction properties of metal-polymer pairs operating in a sea water simulator 金属-聚合物对在海水模拟器中的耐磨性和减摩性能研究
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2022-12-15 DOI: 10.17212/1994-6309-2022-24.4-84-97
D. Bataev, R. Goitemirov, P. Bataeva
Introduction. Sea water is an aggressive environment that causes corrosion, erosion, and cavitation when moving at high speeds of steel, cast iron, bronze, or babbit parts that work satisfactorily only with lubrication. In this case, oil stains are often released into the water, which leads to pollution of the water basin. Materials and methods. To study the wear and friction coefficient, the following materials were chosen: pure polyamide P-610 and antifriction materials based on it Maslyanit D and Maslyanit 12. The following metals were used as the material of the counterbody: stainless steel Cr18Ni9Ti, bronze (9 % Al; 2 % Mn), and titanium alloy VT-3. Results and discussion. It is established that the materials of the “maslyanit” group have significantly better wear resistance and antifriction properties than pure polyamide P-610. It is shown that the reason for such properties of Maslyanit D and Maslyanit 12 is the presence of solid and grease lubricants in its compositions, which simultaneously also play the role of a plasticizer. Finely dispersed metal fillers favorably affect the heat rejection from the friction zone and the growth of the crystalline phase of the polymer. A positive effect of iron minium on the friction of Maslyanit 12, which causes the generation of a protective anti-friction film on the working surfaces of the friction pair, is revealed. A decrease in wear and friction coefficient is found as the purity class of the metal surface increased. The predominantly fatigue mechanism of wear of polymeric materials during friction in a sea water simulator is confirmed. The results of testing Maslyanite 12 in a real marine environment confirmed the positive characteristics of Maslyanit 12.
介绍海水是一种侵蚀性环境,当钢、铸铁、青铜或巴氏合金零件高速移动时,会导致腐蚀、侵蚀和气穴,而这些零件只有在润滑的情况下才能正常工作。在这种情况下,油污经常会释放到水中,从而导致水池受到污染。材料和方法。为了研究磨损和摩擦系数,选择了以下材料:纯聚酰胺P-610和基于它的减摩材料Maslyanit D和Maslyanite 12。以下金属被用作沉头体的材料:不锈钢Cr18Ni9Ti、青铜(9%Al;2%Mn)和钛合金VT-3。结果和讨论。已经证实,“maslyanit”组的材料比纯聚酰胺P-610具有明显更好的耐磨性和减摩性能。研究表明,Maslynit D和Maslynit 12具有这种性能的原因是其组合物中存在固体和油脂润滑剂,它们同时也起到增塑剂的作用。精细分散的金属填料有利地影响摩擦区的散热和聚合物结晶相的生长。揭示了微量铁对Maslyanit 12的摩擦的积极影响,其导致在摩擦副的工作表面上产生保护性抗摩擦膜。发现磨损和摩擦系数随着金属表面纯度等级的增加而降低。证实了在海水模拟器中摩擦过程中聚合物材料磨损的主要疲劳机制。在真实海洋环境中测试Maslyanite 12的结果证实了Maslyanit 12的阳性特征。
{"title":"Studies of wear resistance and antifriction properties of metal-polymer pairs operating in a sea water simulator","authors":"D. Bataev, R. Goitemirov, P. Bataeva","doi":"10.17212/1994-6309-2022-24.4-84-97","DOIUrl":"https://doi.org/10.17212/1994-6309-2022-24.4-84-97","url":null,"abstract":"Introduction. Sea water is an aggressive environment that causes corrosion, erosion, and cavitation when moving at high speeds of steel, cast iron, bronze, or babbit parts that work satisfactorily only with lubrication. In this case, oil stains are often released into the water, which leads to pollution of the water basin. Materials and methods. To study the wear and friction coefficient, the following materials were chosen: pure polyamide P-610 and antifriction materials based on it Maslyanit D and Maslyanit 12. The following metals were used as the material of the counterbody: stainless steel Cr18Ni9Ti, bronze (9 % Al; 2 % Mn), and titanium alloy VT-3. Results and discussion. It is established that the materials of the “maslyanit” group have significantly better wear resistance and antifriction properties than pure polyamide P-610. It is shown that the reason for such properties of Maslyanit D and Maslyanit 12 is the presence of solid and grease lubricants in its compositions, which simultaneously also play the role of a plasticizer. Finely dispersed metal fillers favorably affect the heat rejection from the friction zone and the growth of the crystalline phase of the polymer. A positive effect of iron minium on the friction of Maslyanit 12, which causes the generation of a protective anti-friction film on the working surfaces of the friction pair, is revealed. A decrease in wear and friction coefficient is found as the purity class of the metal surface increased. The predominantly fatigue mechanism of wear of polymeric materials during friction in a sea water simulator is confirmed. The results of testing Maslyanite 12 in a real marine environment confirmed the positive characteristics of Maslyanit 12.","PeriodicalId":42889,"journal":{"name":"Obrabotka Metallov-Metal Working and Material Science","volume":" ","pages":""},"PeriodicalIF":0.4,"publicationDate":"2022-12-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49070678","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}
引用次数: 0
Formation features of a welding joint of alloy Ti-5Al-3Mo-1V by the friction stir welding using heat-resistant tool from ZhS6 alloy 用ZhS6合金耐热工具搅拌摩擦焊接Ti-5Al-3Mo-1V合金焊接接头的成形特征
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2022-12-15 DOI: 10.17212/1994-6309-2022-24.4-53-63
A. Amirov, E. Moskvichev, A. Ivanov, A. Chumaevskii, V. Beloborodov
Introduction. The technological process of fabrication products from titanium alloys is often complicated by low quality of welded joints during electric arc or gas-flame welding operations due to high residual stresses and deformations. An example of a successful solution to this problem is the development and implementation of such high-tech processes of metal joining as friction stir welding, which does not refer to the methods of fusion joining. Friction stir welding as an advanced technology is used to obtain joints of “soft” metallic materials, such as aluminum. For “hard” metallic materials, friction stir welding has been limited due to the high demands on welding tools. The aim of this work is investigation of the possibility of using a tool made of the nickel-based heat-resistant alloy ZhS6U in friction stir welding of the titanium alloy Ti-5Al-3Mo-1V. Results and discussion. Optical and scanning electron microscopy results revealed that the structure of the weld is typical of this type of welding, gradient, consisting of a heat-affected zone, thermo-mechanical affected zone and a stir zone with a fragmented structure. When varying welding parameters, it is shown that the defectiveness of the weld is affected to a greater extent by the axial load on the tool, which is caused by a significant difference in the thermal effect on the material. Metallographic analysis methods revealed dissolution of welding tool material fragments in the stir zone of the non-detachable joint. Fractographic analysis of the fracture surface shows that the fracture in the weld zone is ductile, although in this case there are brittle bridges. Varying the parameters of friction stir welding made it possible to obtain an indissoluble joint with at least 90 % of the strength of the base metal.
介绍。在电弧或气焰焊接过程中,由于残余应力和变形大,焊接接头质量低,使钛合金制造产品的工艺过程变得复杂。成功解决这一问题的一个例子是开发和实施了搅拌摩擦焊等金属连接的高科技工艺,而不涉及熔合连接的方法。搅拌摩擦焊是一种先进的焊接技术,用于获得“软”金属材料(如铝)的接头。对于“硬”金属材料,由于对焊接工具的要求很高,搅拌摩擦焊一直受到限制。本工作的目的是研究在Ti-5Al-3Mo-1V钛合金的搅拌摩擦焊接中使用镍基耐热合金ZhS6U制成的工具的可能性。结果和讨论。光学和扫描电镜结果表明,焊缝结构为典型的梯度焊接,由热影响区、热机械影响区和具有破碎结构的搅拌区组成。当焊接参数变化时,焊缝的缺陷更大程度上受工具上的轴向载荷的影响,这是由材料热效应的显著差异引起的。金相分析方法表明,在不可拆卸接头的搅拌区有焊接工具材料碎片的溶解。断口形貌分析表明,焊接区的断口是延性的,尽管在这种情况下存在脆性桥。改变搅拌摩擦焊接的参数可以获得不溶接头,其强度至少为母材的90%。
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Obrabotka Metallov-Metal Working and Material Science
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