Rationalization of modes of HFC hardening of working surfaces of a plug in the conditions of hybrid processing

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 electric power units for integral processing of punch-type parts allows increasing the productivity of surface hardening by 36–40 times and reducing energy costs by 6 times.