Vol 2, No 2 (2015)

Full Issue

COOPERATION BETWEEN THE LEADERS OF THE FIRST TOGLIATTI HIGHER SCHOOL, SELF-GOVERNMENT INSTITUTIONS AND HEADS OF CONSTRUCTION SITES OF THE CITY (IN 1951-1971)

Adaevskaya T.I.

Abstract

The article presents a wide range of previously unknown pages of the history of Togliatti State University (TSU) related to the activities of the university leaders in the first two decades of the high school activity. The paper covers the period from its founding in 1951 as a branch of the evening school of the Kuibyshev Industrial Institute of Kuibyshevhydrostroy in Stavropol-on-Volga till 1971, when Togliatti Polytechnic Institute (TPI) had got material and technical resources, scientific and pedagogical staff, and foundations for the development of scientific schools.

For the first time, the article presents in its scientific consideration the relevant biographical information – in its chronological sequence – about all six leaders of the higher school: the heads of the evening department of the Stavropolsky branch of Kuibyshev Industrial Institute of Kuibyshevhydrostroy D.E. Churkin and V.N. Nikolayev, the directors of the Stavropolsky branch of Kuibyshev Industrial Institute V.N. Zubkov, V.L. Bondarev and E.F.Vinokurov, the rector of Togliatti Polytechnic Institute A.N. Reznikov. The author reveals the peculiarities of the interaction of the university leaders, the city administration and construction projects aimed at expanding the scientific, educational and pedagogical tasks and creating a common educational network of the city. Two phases of development of the university are considered in details: first, the initial period of establishment of the evening school of KII of KHS before the city of Stavropol-on-Volga had been transferred, and the early years of the new city under construction. The research reports the effective support provided to the branch by the head of "Kuibyshevhydrostroy" I.V. Komzin, and his teaching activity as a professor.

The second period is when an independent higher school was created in Togliatti – Togliatti Polytechnic Institute (TPI). The creation of the first independent university in Togliatti is connected with the name of Professor A.N. Reznikov, an honorary citizen of the city of Togliatti. The article considers its effective cooperation with the Volga automobile factory and other factories of the country; studies the basic activities of 12-year history of TPI when the higher school was not only expanding, but also became a scientific and educational center of the Volga region.

Frontier Materials & Technologies. 2015;2(2):15-25
pages 15-25 views

CURRENT STATE OF DEVELOPMENT OF GEOMETRY-GRAPHICS CULTURE AND COMPETENCE OF FUTURE PROFESSIONALS

Amirdzhanova I.Y., Vitkalov V.G.

Abstract

The article considers the current state of development of geometry-graphics culture and competence of future professionals taking into account the rapid development of information technologies which led to the transformation of content of engineering effort and the change of requirement for the future engineers training and assessment of their professional qualities, i.e. change of the competence of future professionals. The authors define the integral notion “graphics culture” which includes modern knowledge and skills in the field of engineering and computer graphics and the ability for creative activity as the implementation of graphics culture principle is impossible without knowing of visual graphical language of professional communication which is the international language of professional technical communication of engineers, understandable without verbal support. The authors analyze the classical geometry-graphics training in technical colleges which are supported by two disciplines – perspective geometry and engineering graphics and modern graphics training including 3D modeling which improves the performance and quality of modeling, its variability and visualization. The article includes the conclusion that the graphics education is the necessary component of content of general higher education and only being represented in the following conjunction: scientific discipline – perspective geometry and its modeling ideology and practical discipline – engineering graphics as graphical documenting supported by computer technologies, can provide the students for acquiring of competences not only in the sphere of engineering graphics but also in general-engineering and special disciplines up to the practical use at the production site, and, consequently, will improve their graphics culture which is determined by the high degree of personal development.

Frontier Materials & Technologies. 2015;2(2):26-31
pages 26-31 views

DEVELOPMENT AND COMMERCIAL IMPLEMENTATION OF HIGH PERFORMANCE MANUFACTURING AND ENVIRONMENTALLY APPROPRIATE TECHNOLOGY OF SURFACE PLASTIC DEFORMATION OF CARS PARTS

Bobrovskiy N.M., Melnikov P.A., Bobrovskiy I.N., Levitskih O.O.

Abstract

The article covers the foreign and domestic experience in development of dry processing technologies. The authors give the results of the introduction of dry processing technologies (cutting, turning, milling, drilling) on the manufacturing companies in Germany. The article presents the analysis of lubricoolants consumption carried out at the JSC "AVTOVAZ", and describes the negative impact of lubricoolants on the human organism and the environment. Possible pathways of lubricoolants components to the atmosphere and soil are described.

Lubricoolants, in most cases of technological process engineering, are considered to be the obligatory components. The authors described three basic missions of lubricoolants: cooling, lubrication, and chip clearance that are essential for steady process behaviour.

The article describes the influence of lubricoolants deletion from the treatment process. The authors compared the microrelief with the base and the proposed processing technologies and developed the phenomenological model of wear of tools made of polycrystalline material with a homogeneous structure when processed by surface plastic deformation. To exercise the stochastic nature of impact of tool roughness on its wear process, the algorithm of tool surface microgeometry forming was developed. While solving the problem of automation of determining the area of tool work surface wear the calculation algorithms and IZNOSOMER software were developed. The system has the advanced capabilities to create a user interface, a wide range of functions, methods, and properties necessary for solving applied computational and engineering challenges. The solutions obtained are based on the use of domestic technology and tools only, and allow rejecting the purchase of import equipment at the cost of up to EUR 1 million per unit, by increasing the loading of machine-building enterprises of the Russian Federation. Processing without lubricoolants technology eliminates the fire hazard from oil lubricoolants, environmental pollution and harm to human health.

Frontier Materials & Technologies. 2015;2(2):32-37
pages 32-37 views

EXPERIMENTAL STUDY OF THERMAL PROCESSES WHEN STRENGTHENING THE METAL-CUTTING TOOLS IN LOW -TEMPERATURE PLASMA

Brzhozovsky B.M., Martynov V.V., Zinina E.P.

Abstract

The article gives the results of experimental study of thermal processes when strengthening the metal-cutting tool in low-temperature plasma of combined discharge using the “Chrom” plant.

The first and the second stages of study identified the influence of fed to the processing zone SHF-power on the passage of temperature front in the “plasma – tool – holder” system in the process of tool heating and cooling and the forming of temperature values in the tool holder body out of the zone of plasma influence, i.e. lagged temperature.

The results of the first stage of study made it possible to identify that the lagged temperature increment depends on the degree of the ambipolar process reaction both near the plasma low bound (on the low levels of fed SHF-power) and within the whole drift space (on the high levels of fed SHF-power).

The results of the second stage showed that the domination of tendency to propagation of large flows of heat fed from plasma to the tool space at the initial stages may lead to the over-heating and tool base tempering. The reason is the “closing” of heat in the heating zone which propagation velocity is notably higher than the temperature front propagation velocity. It caused by the fact that, for this moment, the channel for heat rejection through convective emission and to the massive heat elements (tool holder and tail end) is not formed yet.

During the third stage, while studying the influence of temperature rate of change on the tool physical and mechanical properties formed in the process of its production, the authors revealed that the change of temperature increase rate and plasma turn-off time may change considerably the tool service reliability.

In the whole, the results of research made it possible to display that the process of heat flow propagation in the plasma treatment zone should be controlled to get the reproducible strengthening results complying with the criteria of creation of a course with a specified structure and physical and mechanical properties on the tool working part surface.

Frontier Materials & Technologies. 2015;2(2):38-43
pages 38-43 views

PROCESS APPROACH TO THE ORGANIZATION OF INFORMATION SYSTEM FOR MATERIALS MACHINABILITY ESTIMATION

Vaskin K.Y., Khripunov N.V.

Abstract

System approach is widely used in modernization of business-processes, organizational structure, corporate documentation procedure and economical information systems. The application of methods of system analysis when introducing the results of engineering research is not covered sufficiently today, that is why the aspects of work related to the application of IDEFO notation to the description of the system being worked out upon the results of scientific researches in the field of metal cutting is important now.

The work covers the application of methods of system analysis when assimilating the results of researches of assessment of metal cutting tool wear rate using the acoustic emission of cutting process. The authors used the analysis of processes in IDEFO notation to describe the developed information system for material machinability estimation. 

The authors developed the context diagram containing the external interactions of the analyzed system. The internal interactions of the analyzed system at the high decomposition level are displayed on the diagram of decomposition of the first level. The authors carried out the structuring of system functions and necessary for system functioning resources within the frames of input, output, supporting and regulating parameters of the processes. The article offers the methods of assessment of machinability based on the use of visual and numeric representations of the information and the application of modern technologies of semi-structured information processing. 

The results of the research showed that the use of the process analysis according to the IDEFO methodology is the effective tool allowing at the stage of the research results implementation to structure the information interactions within the frames of input, output, supporting and regulating parameters of the processes at different levels of the system detailing. The application of the system analysis methods to the description of the system for machinability assessment using the acoustic emission signal allowed identifying the basic requirements to the information system which specialization is possible within the frames of accepted methodology when moving to the lowest levels of decomposition in the system processes description.

Frontier Materials & Technologies. 2015;2(2):44-49
pages 44-49 views

THE DEVELOPMENT OF A COMPUTER MODEL OF THE «ELECTRIC NETWORK - SEMICONDUCTING COMPENSATOR - RESISTANCE WELDING MACHINE» SYSTEM

Glibin Y.S., Shevtsov A.A.

Abstract

The article covers the issue of simulation of a static semiconducting compensator of the total power inactive components operating in AC power single-phase network for a spot resistance welding machine. The authors showed the wide use of resistance welding in modern production. The disadvantages of modern power supplies of resistance welding machines are defined according to their energy efficiency. The authors made a conclusion that it is possible to reduce energy consumption by 20-40% using special devices - semiconducting compensators. Since both the resistance machine and compensator operate at high currents and voltages, and the cost of their electrical components is large enough, the task of creating a computer simulation model of the "Industrial network - Semiconducting compensator - Resistance welding machine” system was set. As a tool, the Matlab Simulink software was selected, because it allows you both to simulate the electrical elements and perform mathematical and logical operations necessary to describe the algorithm of control system work. The article represents all simulation model parts: the network, the compensator power circuit, the compensator control system, the resistance welding machine. The authors described in detail the process of selection of a particular Simulink block for the model implementation and introduced mathematical expressions forming the basis for the work of compensator key management system and the basis for the resistance machine simulation. The authors carried out the simulation of the system work and presented the results in the form of timing diagrams of currents and voltages. System operating troubles are displayed when the nominal values of electrical elements of the compensating device are selected improperly. The authors made the conclusion on the possibility of applying the developed model for the study of various modes of the compensator operation, as well as for selection of nominal values of its components.

Frontier Materials & Technologies. 2015;2(2):50-57
pages 50-57 views

EMPIRICAL TECHNIQUES FOR RESOLVING CONTRADICTIONS IN TECHNICAL PROBLEMS

Gordeyev A.V., Borodynkina D.L.

Abstract

The well-known approach to solving technical problems by resolving conflicts through the use of empirical methods is rather cumbersome, and makes it difficult to study it in the course of educational process. The aim of the paper is to develop such a system of empirical methods that would allow studying it within the educational program of training an engineer without reducing significantly its effectiveness. As a part of this goal, the author analyzes well-known systems of empirical methods of solving technical problems with regard to the field of "Mechanical Engineering", and makes an attempt to reduce the number of techniques without losing their effectiveness due to their specialization, as well as by combining well-known methods. The proposed approach allows mastering the method of empirical techniques within the educational process.

As a result, a list of empirical methods and techniques of solving technical problems in the field of mechanical engineering, including 10 techniques: partitioning – aggregation (partition of the object, task sharing, optimization, nesting), elasticity (elastic element, inflatable element), other way (opposite position, opposite action, prior action, asymmetry), curvilinearity (curvilinear element, rotation, rolling), dynamism (mobility, adaptability, intermittence), analogy (a copy of the object, the technical counterpart, natural analogue), damage to the good (usage, intensification, adding, cheap fragility, waste), state (aggregate state, texture, porosity, heterogeneity), mediator (modified object, the third object), physical fields (the field, a combination of fields, physical effects).

Examples of application of empirical methods and techniques in solving engineering technology are given in the article.

The proposed system of empirical methods allows to study them in classes on technical creativity within the time allotted in the curriculum, and use them both for solving educational problems in discipline "Mechanical Engineering", coursework designing and further engineering practice.

Frontier Materials & Technologies. 2015;2(2):58-63
pages 58-63 views

METHODOLOGY AND PRACTICE OF ORGANIZING AND CONDUCTING OF SAFETY MONITORING OF WORK TRAINING LABORATORIES

Gorina L.N., Danilina N.E., Freze T.Y.

Abstract

The increased background noise exceeding limit values is a danger to the physical and mental health of a human. Preparation of experts for the metal-working complex is carried out in a university laboratory that is equipped with professional stands and machines used in production process. Metal-working machines are a source of noise. Indoor noise is created by the operation of machine tools, welding equipment and test benches for components and automotive parts. The indoor and outdoor areas, where the security of people may depend on the legibility of the sound generated by means of radio warning, should be provided with measures to ensure the optimum volume and distinguishable sound. Therefore, monitoring of educational process by the acoustic factor is the important procedure for the safety of the educational process.

The purpose of the study is to improve the quality and security of the educational environment through acoustic monitoring of the educational process. As an algorithm of acoustic monitoring of the educational process the authors can offer the following sequence: an inventory of disciplines, laboratories, machine tools and instrument base, which have a negative impact on students at an educational institution, identification of dangerous and harmful factors that influence negatively on the students at the educational institution on the basis of the register, formation of the normative and legal base according to the acoustic factor, instrumental measurement of sound level, octave sound pressure level, the level of infrasound in school and industrial laboratories, processing of the experimental data, comparison of the results to the normative values, formulation of conclusions and recommendations aimed to improve the acoustic indices of educational institutions.

Frontier Materials & Technologies. 2015;2(2):64-68
pages 64-68 views

THE STUDY OF ACCURACY OF PROCESSING ON PRECISION PRODUCTION EQUIPMENT

Gorshkov B.M., Remneva O.Y.

Abstract

Metal-cutting machines involve complex production systems changing their parameters during the treatment process that results in degradation of processing accuracy. There are many factors influencing the processing accuracy but the main factor is the precision of production equipment. The potentialities of classical approaches to the machines accuracy increase have been practically exhausted and now they make no economic sense. That is why the article covering the study of accuracy of processing on precision production equipment is very important now.    

The article describes the results of the study of accuracy of processing of deep holes using the 2A459AF4 precision horizontal coordinate boring machine.

The goal of the study is to prove the influence of elastic power deformations of the frame construction (bending and torsion) of precision horizontal coordinate boring machine on the processing accuracy. 

The measurements of deviation from circular form of a hole were carried out on the base of a special unit under the conditions most closely resembling the real factory world. Basing on the results of the holes selection, the authors plotted the dot diagrams visually indicating the character of deviation of the processed hole axis during its processing. The authors determined that the value of the hole axis deviation in two perpendicular planes is an unstable quantity and depends on the position of moving elements of the machine processing system during the process of treatment. When the holes are located closer to the table reflector, the value of axis deviation reduces. The presence of elastic power deformations of the frame construction causes the blank part displacement and, subsequently, the processed hole axis deviation about the tool axis.

The study was carried out according to the own methods based on the following application software package: Kompas 3D V12, ANSYS Workbanch, MathCAD. 

Frontier Materials & Technologies. 2015;2(2):69-74
pages 69-74 views

THE TECHNOLOGY OF ARC WELDING OF SMALL-SIZE COMPONENTS OF NUCLEAR PLANTS UNDER THE SHIELDING GAS HIGH-PRESSURE

Kazakov Y.V., Kaplin A.V., Kostyuchenko N.A., Andreev S.A.

Abstract

The article presents the results of research of the influence of argon and helium high pressure on the welding arc process parameters and the samples of nuclear plants components with the increased internal pressure. The authors described the method for filling up and the special features of equipment for the components sealing. The installation is a chamber where the electrode and the product are placed. The arc is stricken by contact process with electromagnet that rises the electrode simultaneously with the welding process start. The increased value of the no-load voltage is the feature of welding power source. The experiment was carried out on the copper plate welded in the up to 15MPa helium and up to 10MPa argon environment. The research showed that with the helium pressure moving higher for each 1 MPa in the currents range of 25…50 A the welding arc voltage increases by 1,6…2 V. It influences much the quality of welding seams of small-size components of nuclear plants. The research showed that the weld geometry factor changes when welding in the increased pressure environment. The authors specified the optimal design of welded joints of small-size thin-walled nuclear plants components with the increased internal pressure. The technology of increased pressure welding can be used both for production of components made of pore-formation sensitive metals and for welding seam defects repair. The experiment on determination of required pressure was carried out on the rejected edge welds made of AD-1 aluminum alloy. The research showed that the rewelding of aluminum components with the rejecting pores at helium pressure of 0,6 MPa and higher corrects the defects.

Frontier Materials & Technologies. 2015;2(2):75-80
pages 75-80 views

THE IMPROVEMENT OF QUALITY OF HARD-ALLOY TOOLS AND PARTS BY MEANS OF CREATION OF SPECIFIED LEVEL OF RESIDUAL STRESS IN THE SURFACE LAYER

Kiselyov E.S., Nazarov M.V.

Abstract

The article covers the issues of ensuring quality of hard-alloy tools and parts when producing them by means of rational use of ultrasonic fluctuations energy. It is well-known that one of the key indicators of quality of the surface layer of parts or tools is the lack of stretching residual stresses. It is especially important for the tools used for high-speed processing of aluminum alloys blank parts which are not exposed to the drawing of wear resistant coatings, and also for the crown bits and various hard-alloy parts which are widely used in modern machines and mechanisms. As a rule, the blank parts to be produced are processed by grinding at final stages of technological process, after which the stretching residual stresses are inevitable. For their relaxation, thermal treatment or natural aging is used in the production that increases the production cycle and the cost of production. For this purpose, the authors offered to use the ultrasonic field energy; in this connection, special installations were developed and the researches were conducted. During the research, the regression dependences of residual stresses on the parameters of thermal power intensity (the components of cutting forces and the contact temperature in the zone of flat diamond grinding of samples made of ultra finely-divided hard alloy) and the elements of processing mode (the longitudinal conveying speed and the cutting depth) were received. The residual stresses were controlled by means of domestic “Rikor-4” refractometer.. During processing, the authors carried out the assessment and the structural phase changes in the surface (using the x-ray measuring “Rikor-7” complex). The results of researches allowed to determine the velocity of ultrasonic relaxation and the elements of its mode.

Frontier Materials & Technologies. 2015;2(2):81-85
pages 81-85 views

IMPROVEMENT OF THE EFFICIENCY OF TECHNOLOGY OF ALUMINUM-SILICON ALLOYS MICRO-ARC OXIDATION

Krishtal M.M., Ivashin P.V., Polunin A.V., Borgardt E.D., Tverdohlebov A.Y.

Abstract

The article covers the issue of improvement of micro-arc oxidation of the most used aluminum casting alloys - aluminum-silicon alloys (silumins). Using the method of micro-arc oxidation, the authors used the AK6M2 and AK9pch silumins samples to get the oxide layers samples, synthesized in the base-composition electrolyte and adding to the electrolyte a small amount of nano-sized silica dioxide powder SiO2. The authors carried out the experimental study of the micro-arc oxidation process performance, the transverse structure of the obtained oxide layers, their phase composition, surface morphology, microhardness, tribological and thermal insulating characteristics. It was found, that the electrolyte modification with nanosized silicon dioxide powder SiO2 significantly increases the productivity of micro-arc oxidation process. The oxide layers formed in the electrolyte, modified by silicon dioxide nanoparticles, display the improved transverse macrostructure and microrelief in comparison with the base variant. The authors found out the simultaneous increase of high-temperature strong phases content and the reduction of metastable low-temperature phases content in the oxide layer. The study revealed the increase of microhardness and wear resistance of the oxide layers, as well as the significant reduction of thermal conductivity of the oxide layers synthesized in the electrolyte when adding silicon dioxide nanoparticles.

Frontier Materials & Technologies. 2015;2(2):86-93
pages 86-93 views

SIMULATION OF INFLUENCE OF BASING HOLES RELATIVE POSITION ON THE ACCURACY OF LOCATION OF RMS AUTOMATICALLY CHANGEABLE UNITS

Levashkin D.G.

Abstract

The article covers the issues of provision of accuracy of location of automatically changeable units when repackaging the work station of repackaged production systems. The study showed the influence of basing holes relative position on the accuracy of location of automatically changeable units during multisided treatment of parts. To resolve the issues of multisided treatment of parts, the author suggested the model of automatically changeable unit – part carrier for simulation of issues of assurance of accuracy of location on the work station of repackaged production system. The author offers the carrier design in the form of a prism where the basing holes are located on the side edges, and the tool set and the parts are installed in the plane of each edge. In this case, the parts position dimensioned repetitiveness against the work station production units and the equal structural stiffness of carrier body in the directions of parts treatment. The article considers the model of system of equally spaced basing holes for simulation of the carrier accuracy of location. The parameters characterizing the accuracy of processing of each basing hole are defined on the basis of dimensional analysis. The study showed the influence of relative position of each basing hole of the carrier on the accuracy of the part processing. To specify the conditions of treatment of basing holes using the automated equipment, the author determined the parameters of treatment which should be ensured to resolve the issues of accuracy of location of the carrier on the work station. The requirements for technology process of production of basing holes were determined on the basis of simulation of dimensional conjunctions. The study showed the necessity of taking into account the decrease of accuracy of their relative position in the result of processing.

According to the simulation results, the ensuring of required relative position of basing holes during their processing will allow to meet the requirements for relative position of the carriers of the repackaged production systems.

Frontier Materials & Technologies. 2015;2(2):94-99
pages 94-99 views

QUALITY MANAGEMENT OF THE BLADES SURFACE LAYER UNDER DEEP PROFILE GRINDING

Makarov V.F., Nikitin S.P.

Abstract

The article provides the system oriented analysis regarding surface treatment quality after deep profile grinding of complex shapes on a multiaxis machine. This method implies using an algorithm of actions to ensure the quality of deep profile grinding of blades, a mathematical model of heat-dynamic system of a grinding machine in a block diagram form, taking into account the cutting process. The algorithm involves elucidation of the dynamic state of a technological system based on the mathematical model of heat-dynamic system of the grinding machine with consideration of dynamics of elastic, thermal and working processes. The dynamic state of the technological system determines the conditions of deep grinding process. As it is well known, with increasing depth the grinding process can become unstable. In conditions of instability, execution or achievement of specified quality parameters is impossible. To ensure stability of the process it is necessary to receive on the basis of a mathematical model the static and dynamic characteristics which will define the mutual displacement of the grinding disk and a workpiece, the current cutting depth, strength and temperature fluctuations in the cutting zone. The proposed mathematical model allows predicting the removal of material, grinding disk wear and roughness of each surface, based on the cutting modes, characteristics of the disk, dynamics of elastic, heat and work processes in the technological system. Knowledge of the impact of the cutting modes and disk characteristics on the quality of each of the treated surfaces enables to determine analytically the optimal characteristics of the grinding disk and grinding modes to ensure the specified quality parameters of the surface layer of the gas turbine engine blades: surface roughness, physical and mechanical condition (cold hardening, residual stresses), accuracy. This technique allows managing the process of deep profile grinding to achieve the desired surface quality parameters, dimensional accuracy of the profile of the gas turbine engines blades, and increase of processing performance on multi-axis machine of complex shape profiles.

Frontier Materials & Technologies. 2015;2(2):100-103
pages 100-103 views

MATHEMATICAL MODEL OF FORMING OF MICRORELIEF OF SHAFT JOURNAL WHILE PROCESSING BY DIAMOND BURNISHING

Melnikov P.A., Pakhomenko A.N., Lukyanov A.A.

Abstract

The performance characteristics of the products are determined considerably by the technology process of their production. Modern machine industry sets the requirements to the parts surfaces operating in the friction conditions and the availability of regular microrelief. This work offers the technology and the mathematical model for calculation of the microrelief of processed surface of shaft journal for the cup-type seal. While studying the cup-type seal – shaft friction couple, the main cauces for its wear were determined.

The authors considered the schemes of applying of regular microrelief using diamond burnishing and the schemes and profilograms of surfaces with obtained grooves systems. The authors classified the microreliefs obtained in the result of vibro-burnishing and determined the dependence of microrelief nature on the processing parameters.

According to the mechanical engineering development trend, the authors proposed the change from one parameter describing requirements to the part’s surface microgeometry to the requirement in the form of regular microrelief availability.

The article shows the results of the mathematical model calculation of the diamond burnishing processing which allows to simulate the relief of processed surface depending on the parameters and processing conditions.

The authors obtained the results of simulation of processed part during diamond burnishing with mode superposition. Comparing the simulation results with the theoretical results, it is possible to estimate the adequacy of mathematical model calculations.

The authors made the conclusions on the possibility of using a mathematical model to estimate the obtained microrelief on the part surface after the burnishing with the mode superposition. The results of theoretical research which are used as the base for mathematical model of the burnishing process with the mode superposition correlate with those obtained in reality.

Frontier Materials & Technologies. 2015;2(2):104-111
pages 104-111 views

THE ANALYSIS OF HIGH-VOLTAGE PULSE WELDING WITH THE MAGNETIC PULSE DRIVE

Merkulov R.V.

Abstract

The goal of this work is to analyze the process of pulse high-voltage compensator discharge welding using the magnetic pulse drive to obtain the joints of heterogenic parts of different thickness.

The analysis of high-voltage pulse welding was carried out on the basis of electrodynamics, the theory of electric erosion machining, and the dislocation theory of solid phase joints formation. The quality of welded joints was evaluated according to the results of mechanical performance tests, thermal cycling tests, metallographic examination of optical and electron-beam microscopy.  

Experimental research data processing, the analysis of expression of magnetic pressure in terms of equipment parameters specified the necessity of research of characteristics of versatile surge-current generator. The author determined the natural and operating frequency of discharge circuit when connecting a certain number of sections with different types of standard pulse condensers using low-inductance tubes. Records of measurements of natural and operating circuit parameters when connecting accumulator and induction dynamic drive sections were carried out using modern digital equipment.     

In the result of analysis of high-voltage pulse welding with magnetic pulse drive it was established that when using magnetic pulse drive with origin gap, it is possible to control energy input into welding area at the account of variation of push bar mass and the gap width. The more are the origin gap and the moving elements mass, the more is the thermal action quantity. When welding the large-sized core parts (d=15–20 мм), it is necessary to use high-frequency current pulse generators (with natural frequency of more than 50 kHz) ensuring arc discharge polarity inversion and, as a consequence, the extension of area of flat part heating at the account of the “magnetic blow” effect.

Frontier Materials & Technologies. 2015;2(2):112-116
pages 112-116 views

PRINCIPLES OF CREATING THE SYSTEM OF COMPUTER-AIDED DESIGN OF PRODUCTION OPERATIONS IN MULTIPRODUCT MANUFACTURING

Mitin S.G., Bochkaryov P.Y.

Abstract

The article considers issues of increasing efficiency in multiproduct machining manufacturing systems by complex automation of production preparation stage. After analysis of modern software possibilities for design automation their shortcomings come to light and the principles are formulated for creation of integrated design and process planning system that ensures effective interaction at various design stages. As a basis for making rational decisions, the automated design system for production operation takes the central place in the integrated technological process planning system. In the course of development of the automated design system for production operations the approaches are found to formalization of design procedures by means of mathematical modeling. An important feature of the proposed models and techniques is the accounting of all planned nomenclature of the processed components as well as orientation to the current state of a production system. For the procedure of equipment generation the model is described with application of Petri nets that allows creating a set of feasible options of cutting and auxiliary tools for all planned nomenclature of the processed components. Elimination of irrational options can be carried out by using criterion of uniformity which ensures invariance of operation structures. For modeling the procedure of generating possible process steps sequences, the graph theory is used. Modeling of procedures for selection of rational equipment sets and operation structures is carried out simultaneously. To do this, the authors suggest using dynamic programming, therefore the system is optimized in general and there is no need for examining of all possible options. Criteria of optimization are the total processing time of all planned components and number of tool changes. In the conclusion of the article the ways of further development and application of the developed system are defined.

Frontier Materials & Technologies. 2015;2(2):117-122
pages 117-122 views

THE TECHNOLOGY OF PRODUCING OF STAMP-WELDED LIGHT WEIGHT CASES FOF ELECTRICAL CABLE SEALING

Nescoromny S.V., Strizhakov Y.L.

Abstract

The application of technology of production of light-weighted shielding cases for on-board equipment connectors using the turning method is accompanied by the low coefficient of material using, considerable labour costs, and the increased product weight.

For reduction in weight of electrical plug connectors the authors suggested to produce cases of electrical connectors from a sheet-like material which ensures radio interference caging. Aluminum foil with the thickness of (0,1 ÷ 0,2)∙10-3m has the best indices of low volume weight and shielding.

The suggested technology of production of light weight shielding cases includes the following processes such as the elastomagnetic-pulse stamping (EMPS) of a blank part, the magnetic-pulse welding – forming (EMPF) and the screwthread chasing.

Magnetic pressure in the suggested EMPF scheme influencing blank part walls has the shape-generating effect according to the matrix configuration and the welding effect in the zone of cross threading.

The basic parameters of EMPF modes for different size types of cases made of aluminum foil are the following: the energy stored in condensers batteries, the operating current frequency and the charging volume of capacity storages.

According to the agreement with the Ministry of Education and Science of the Russian Federation, the agreement № 14.574.21.0049 dated the 19.06.2014, the unique RFMEFI57414X0049 identificator, rapid adjusting universal equipment – a double-acting press was built. It ensures both static and pulse load in a single set and allows performing of all stages of technological process of connector cases production in one and the same device.

The double-acting press consists of the process unit for static loading and the pulse current generator with the induction dynamic drive for pulse loading.

To optimize the technology, a discharge processes measuring assembly was installed. It includes the devices for registration of discharge circuit current and its frequency, magnetic pressure and physical parameters of double-acting press, both active and inductive discharge circuit resistance and the capacity storage unit.

The measuring assembly will allow carrying out the analysis of welding joints.

Frontier Materials & Technologies. 2015;2(2):123-129
pages 123-129 views

THE STRUCTURE AND CHARACTERISTICS OF THE OVELAP AREAS DURING THE LASER HARDENING OF STEELS AND IRONS

Ogin P.A.

Abstract

The article considers the issue of wear resistance improvement of working surfaces of the parts of machines, equipment and metal cutting tools. One of the most prospective directions in this field is the thermal treatment of wearing surfaces by means of the action of focused heat flows created by laser light. Modern fiber optic lasers are the most advanced from technology viewpoint. The research and estimation of the structure of the overlap areas during multi-pass laser operation are the key elements of preparing of technology process and influences directly the selection of treatment modes. The author gives the results of experimental research of the influence of fiber optic laser treatment parameters on the state of surface layer of the overlap areas during the multi-pass heat treatment of steels and irons. LKD4-015.150 fiber optic laser was used for experimental research. The treatment was performed in the continuous mode with the partial fusion of processed surface. The process mode was selected according to the data of the work “Modification of steel and iron surfaces using the fiber optic laser”. X12MF steel and SCh21 iron plates 15х15х3 mm in size were used as the samples. After treatment, end surface of each sample was burnished at minimal modes in order to eliminate the additional thermal influence on the structure; after that, microslices were produced on the surface. 4-% alcohol solution of hydrogen nitrate (HNO3) was used as an etchant. The hardness was measured using the Shimadzu HMV-2 microhardness tester. The samples’ structure was studied using the Zeiss AXIO Observer.D1m microscope and the Zeiss LEO1455VP electron scanning microscope.

During this research, the author carried out the analysis of the overlap areas structure and measured their microhardness. The article displays the computational scheme and calculation formula of engagement factor during the multi-pass processing.

Frontier Materials & Technologies. 2015;2(2):130-135
pages 130-135 views

INNOVATIVE METHODS AND CHALLENGES IN HIGH SPEED AND ULTRA-HIGH-SPEED GRINDING

Pilinsky A.V.

Abstract

The review describes latest innovation results and achievements in the field of grinding. Special attention has been paid to new innovative grinding tools such as wheels with minimum quantity of bonds (MQB) having very high porosity and extremely light weight. Perspectives were discussed for making new superabrasive tools with cutting points which have very high strength reaching the strength of synthetic diamonds or even exceeding that.

Special attention has been paid for advanced methods of Creep-Feed Deep Grinding, High-Speed Grinding and Ultra-High-Speed Grinding. Up-to-date combined methods of Super-High Grinding such as Speed-Stroke Grinding, High-Speed-Stroke Grinding, Quick-Point Grinding, and High-Efficiency Deep Grinding and others have been presented and discussed. The most of above mentioned methods are being currently investigated in China, the United States, Japan, Germany and other European countries.

The work discusses requirements to new kinds of equipment and grinding tools for the combined high-speed grinding and ultra-high-speed grinding methods. The new possibilities and areas of application of the High-Speed Diamond Grinding and MQB tools have been also shown. MQB tools are equipped with extruded grits having 4:1 and 8:1 ratio of length to diameter are manufactured by Saint-Gobian Abrasives (USA, France), which is the biggest producer of abrasive and diamond tools in the world.

The article presents practical results of manufacturing experience of China, USA, Germany and Japan in different methods of Super-High and combined methods of grinding.

The list of references includes the works in the field of High-Speed Grinding and other grinding phenomena published by the most prominent and famous researchers in the world.

Frontier Materials & Technologies. 2015;2(2):136-144
pages 136-144 views

CHOICE OF THE PROTECTIVE DELIMITER OF VOLTAGE ON THE EXAMPLE OF THE PULSE VOLTAGE CONVERTER

Pozdnov M.V., Pryadilov A.V.

Abstract

Object of research is the protective limiter used in the raising pulse converter of constant voltage (PCCT). The purpose of work consists in justification of a choice of the limiters necessary for restriction of switching revoltage in power transistors at the safe level, at the set parameters of work of the scheme. In article relevance of application of pulse power supply circuits in modern technologies at various types of loading is considered. On the example of the pulse converter of constant voltage the equivalent circuit showing is shown that switching off of the transistor is followed by an overstrain. For restriction of an overstrain it is offered to use voltage limiter. For the purpose of a rational choice of the limiter it is offered to consider switching processes at switching off of the transistor. The analysis of processes of switching is carried out on the basis of the assumptions which are often used in the analysis of pulse processes of pulse converters of voltage. The temporary chart explaining work of the scheme is provided. The analysis of processes of switching is followed by a conclusion of the analytical ratios reflecting key parameters of switching: level of revoltage, switching time, the energy emitted in the limiter for one period and average power of losses in the limiter. The concept of a relative overstrain which is used for a choice of the limiter and the power transistor is entered. Examples of the elements released by the industry which can carry out functions of limiters are reviewed. The analysis of parameters of the limiters released by various producers is carried out. On the removed analytical ratios and proceeding from the analysis of the parameters provided by producers of limiters recommendations and an estimated technique at the choice of limiters for power supply circuits are provided. A scope of this work are schemes with the transistors working in the key modes, such as schemes IPPN.

Frontier Materials & Technologies. 2015;2(2):145-149
pages 145-149 views

THE PRICIPLES OF SELECTION OF THE ELEMENTS OF PROTECTIVE R-C-VD CIRCUIT USING THE EXAMPLE OF A CONSTANT VOLTAGE PULSE CONVERTER

Pozdnov M.V., Pryadilov A.V.

Abstract

This article covers the principles of selection of protective R-C-VD chain elements using the example of a constant voltage pulse converter (CVPC).

The aim of this research is the reasonable choice of protective chain parameters necessary for keeping the switching over-voltage on a safe level.

The objectives of this work are to describe the processes of formation of switching over-voltages with the partition of switching processes for the periods of time, the revealing of the over-voltages values based on circuit parameters, and the formulation of recommendations on the selection of parameters of protective R-C-VD chains.

The object of this study is the damping (protective) R-C-VD circuit used in the boost constant voltage pulse converter.

The article explains the relevance and the field of application of the issue under consideration. The article presents the mechanism of formation of switching over-voltages in the spurious inductances in the switching circuits. The authors considered the connection diagram of protective R-C-VD circuit for limitation of the over-voltage and the work of a constant voltage pulse converter with R-C-VD circuit in the terms of forming switching over-voltages. For this reason, one circuit operation period was divided into time intervals, each of which describes the circuit operation.

The research was carried out taking into account certain assumptions applicable to the analysis of such circuits. The authors introduce the analytical relations that allow determining the value of switching over-voltage on the basis of the circuit parameters. The authors obtained the relations reflecting the energies transformation between the circuit elements in the process of protective circuit operation. The flow chart illustrating the circuit operation is presented. On the base of the above description of the circuit operation and obtained analytical relations, the criteria for selection of protective R-C-VD circuit elements have been formulated focusing on the features of their selection.

The application field of this research is the schemes with transistors operating in key modes, such as the schemes of constant voltage pulse converter.

Frontier Materials & Technologies. 2015;2(2):150-154
pages 150-154 views

CLASSIFICATION DEVELOPMENT OF CAD/CAM/CAE SYSTEMS FOR SHEET STAMPING BASED ON FACTOR AND CLUSTER ANALYSIS

Pochekuev E.N., Puteyev P.A.

Abstract

In the area of automation of process design and stamping objects there are a great number of commercial software products. Each of them has the tools and features aimed at reducing the complexity and accelerating the design time. The article presents classification of the set of domestic and foreign computer-aided design facilities for multiposition stamping objects and processes (CAD MS). The analyzed CAD systems are described by a number of functional features. Using the method of principal components of factor analysis the authors conduct the search of correlations between the features to reduce their numbers. There are five factors (groups of characteristics of CAD MS). The selected factors are given specific names according to the description of their constituent features. The article describes a structural and logical CAD MS framework for the obtained factors. The percentage of computer-aided systems in each factor is presented. For the construction and classification of certain types of CAD MS the authors use k-medium method of cluster analysis. The number of clusters (CAD model) and their volume is defined. These clusters are the best description of a typical CAD MS. The clusters are given the names, and their functionality is described. The defined clusters and their descriptions are coordinated with heuristic division of CAD according to technological and design features. The largest number of CAD MS from the submitted sample refers to technological clusters. Cluster analysis of the large number of CAD shows that the development of design automation of stamping objects and processes is connected with optimization of the sheet stamping technological process and the use of tools and modules of CAE, as well as the development of libraries of standard parts and assemblies subject to knowledge bases.

Frontier Materials & Technologies. 2015;2(2):155-160
pages 155-160 views

EXPLORATORY DEVELOPMENT OF THE STRUCTURES OF PROGRESSIVE SEPARATING DIES FOR SHEET STAMPING

Pochekuev E.N., Shenberger P.N.

Abstract

The article considers the process of exploratory development of separating dies for progressive sheet stamping. The authors carried out the structure-hierarchical description of progressive separating die constructions and presented the construction schematic structure of the progressive separating die developed on the basis of graph-schemes of units and mechanisms. The authors introduced the notion of multitude, which contains various units, attributes and variables determining the die design as the subsets. During the study, the authors created the conceptual schemes for each group of mechanisms determined by the structural links within the multitude of the structure attributes and displayed possible variants of the die design in the form of “decision” table within the binary space of structure elements, their attributes and values. The die mathematical model (DMM) allowing the development of the design according to the requirements and die parameters specified by design engineer was developed. It was offered to implement the procedure of searching for the variants of die structure on the basis of object-oriented programming methods. The authors implemented the idea of interacting objects (units, mechanisms, parts) as the examples of a specified class, where the classes form the inheritance hierarchy, and created the nested classes system for the units, mechanisms and parts with their properties inheritance.    

The authors created an applied software product (in NX OPEN environment using C# programming language) for the exploratory development of the structure of die equipment using the materials implemented in database. The logic scheme of knowledge base allowed to select the schematic structure determining the variant of die design from the database. Based on the results of the study, the authors developed the procedures of exploratory development of progressive separating dies on the basis of the die mathematical model using the structure-logical and numerical variables.

Frontier Materials & Technologies. 2015;2(2):161-165
pages 161-165 views

WELDING DEFORMATIONS, «SLACK TEMPERATURES» METHOD AND THE STRENGTHENING OF FIXED COLUMNS OF ROOF STEEL TRUSSES

Rodionov I.K., Rodionov I.I.

Abstract

The strengthening of roof steel trusses is often achieved by the increase of columns section by means of joining of columns elements during welding. The welding heats the sections and develops flexural deformations. For rational strengthening, it is necessary to take into account these effects. In this connection, the authors developed the methods for calculation of welded deflections produced when strengthening by means of increase of sections in fixed columns of roof steel trusses. These methods are based on the method of determination of welding stresses and deformations known as the «slack temperatures» method. It takes into account the main characteristics of strengthening: the existence in the strengthened elements of compression stresses developed in the result of load, several longitudinal welding seams, and section complexity. These methods are based on the idea of thermal power division during the welding of elements depending on their thicknesses. In cases of strengthening by weld facing of each seam, the authors determined the distributions of welding stresses separately from thermal power necessary for strengthened and strengthening elements.

The procedure of calculation of welding stresses resulted from thermal power necessary for strengthening elements is the same as their calculation procedure in the unstressed element. When calculating stresses from thermal power necessary for the base elements, the authors take into account the compression stresses from the load.

The torques and, consequently, the column welding deflections are determined according to the mutual actions of shrinkage forces originated in the strengthened and the strengthening elements.

The obtained technique of calculation became the basis for the proving of welding technologies allowing strengthening of columns of steel angle trusses during any forcing, including the maximum permissible computed values, and considerably (up to 30%) increase the effect from the strengthening (in comparison with the traditional technologies).

Frontier Materials & Technologies. 2015;2(2):166-170
pages 166-170 views

THE RESEARCH OF TEMPERATURE DEVIATIONS IN WELDING PROCESS DURING THE DISTURBING ACTIONS

Sidorov V.P., Melzitdinova A.V.

Abstract

The authors offered the methods for determining temperature in the welding zone, taking into account the influence of various disturbances. Basing on these methods, the surface temperature of the heat-resistant steel plates welded by double argon-arc welding without cutting edges is calculated. The authors calculated the thermal cycle of selected point on the outer surface of a part at the distance y = 0,6 cm from the axis of the heating source and obtained the point with the maximum temperature (x = 0.7 cm), for which the influence of permitted deviations in the nominal values ​​of welding conditions (thermal diffusivity, plate thickness) and welding modes (effective power and welding speed) are determined The article gives the values ​​of relation coefficient of disturbance transmission (RCDT). It is the controlled parameter reaction for the change in controlling parameter in relative units in the absence of controlling system. It was found that while controlling the point temperature, the relative influence of welding speed exceeds the influence of effective power while in case of regulation of direct weld penetration there is almost no difference. It is advisable to use the welding speed as the controlling parameter since it does not influence the arc power and does not react in the "power source - arc - welding pool" system. According to the proposed method, the study of temperature change of a point with the coordinate at which the maximum penetration takes place (y = 0.6 cm, x = 1.1 cm) and a point with y = 0,8 cm, х = 1.1 cm. On the basis of the results comparative analysis, to regulate the welding process, it is preferable to select a point with maximum weld penetration as the penetration and temperature deviations at a given point coincide in time.

Frontier Materials & Technologies. 2015;2(2):171-175
pages 171-175 views

SELECTION OF ABRASIVE WHEELS ACCORDING TO THE GRINDING BURNS OF HARDENED PARTS USING DIGITAL TECHNOLOGIES

Soler Y.I., Kazimirov D.Y., Nguyen V.

Abstract

The authors developed the procedure of quantitative assessment of grinding burns on the base of digital technologies. This procedure includes three steps: macrophotography of original surface in the reflected light rays; its digitization using Adobe Photoshop CS6 13.1.2 software and its conversion in the form of raster images of different colours. The advantages of this method are: low labor input, environmental safety and the possibility of wide use for any scientific purpose and in any industrial conditions. It was tested within the pendulum grinding of flat parts made of 30ChGSA hardened steel (σUST=1080 MPa, δE=10%). The parts were ground by different against grains, hardness and porosity wheels: 25AF46K10V5-PО3, 25AF46L10V5-КF35, (92A, 25A)F46L6V24, 25AF46M12V5-PО3, EKE46K3V.

To prove the reliability of this innovative technology of grinding burns assessment, the authors carried out the study of parts microhardness. Taking into account the stochastic nature of grinding, to process the observation results on both grinding output parameters, the authors used the statistical methods which are divided into parametric and nonparametric (in particular, the rank methods). Statistical methods are. The advantages of these methods are the possibility of taking statistical decisions with the given reliability, as well as the assessment of cutting wheels ability not only according to the position measures (averages, medians), but also according to the measures of dispersion: deviations standards, ranges and quartile latitudes. The measure of one-dimension latitudes dispersion is more important while grinding essential parts on pre-set machines to reduce the probability of rejected parts. The study showed that in the conditions of homoscedasticity and normality of distributions violations, it is necessary to use the non-parametric method, wherein the medians and quartile latitudes are used as one-dimensional frequency distributions. The authors revealed the correlation between the position measures for burn density and microhardness while grinding by abrasive wheels using the mode: vc=35 m/s, slo=7 m/min, str=1 mm/double pass, t=0,015 mm, z=0,15 mm, when the increase of burns is accompanied by the reduction of 30ChGSA parts microhardness. The best results according to the position measures were shown by 25AF46K10V5-PО3 wheel, and according to the grinding accuracy - 25AF46L10V5-КF35 wheel.

Frontier Materials & Technologies. 2015;2(2):176-184
pages 176-184 views

ASSESSMENT OF THERMAL CONDITION OF TURNING SCREW TOOLS WITH ANTI-WEAR COATINGS

Tabakov V.P., Sagitov D.I.

Abstract

The process of thread cutting is characterized by more unfavorable factors of cutting process than traditional continuous turning. In this connection, the minimization of these factors influence on cutting tool and, consequently, the improvement of its working ability, is the relevant objection. One of the ways of improvement of the cutting tool working ability is the application of wear-resistant coatings on its working surfaces; that is why the evaluation of influence of wear-resistant coatings compound on the thermal condition of the cutting tool is the important task while developing new more effective wear-resistant coatings compounds. The article gives the results of study of thermal condition of threading tool with one- and multi-elements of nitride coatings (TiN, TiCrN и TiCrZrN) which were applied on the turning thread planes of full profile by the substance condensation in vacuum using the ionic bombardment. The article shows the influence of scheme of thread cutting on the contact characteristics of the cutting process. The article provides the results of finding the contact characteristics of the screw cutting process and thermal condition of turning screw tools with different coatings. It shows the influence of tapping scheme and anti-wear coatings on temperature fields in cutting threaded wedge cutters, and heat balance of screw cutting process. Based on the results of the research, the authors suggest new durable coatings of multi-element and multilayer architecture.

Frontier Materials & Technologies. 2015;2(2):185-190
pages 185-190 views

THE STUDY OF TEMPERATURE FIELD WHEN GRINDING WITH ULTRASONIC ACTIVATION

Unyanin A.N.

Abstract

The application of ultrasonic vibrations power is the promising direction of the grinding process efficiency improvement. To estimate the work conditions of grinding wheel and the quality parameters of the surface layer of a blank part, it is necessary to know local temperatures. However, the analytical research of local temperatures when grinding with ultrasonic vibrations is not carried out.

The goal of this research is the determination of vibrations parameters influence on the temperature field of grinding process.

The research objectives are: the development of physical and mathematical models for calculation of temperature field, methodology, algorithm and software for temperatures calculation, temperature numerical simulation.

Scientific novelty: it is the first analytical research of temperature field when grinding with ultrasonic activation.

The authors developed physical and mathematical models for calculation of temperature field while grinding that take into account the alteration of kinematics of abrasive grains micro-cutting and the mechanical properties of blank part material while grinding with ultrasonic activation, and the parameters dependences characterizing blank part material dispersion resistance and thermophysical properties of interacting objects materials (abrasive grain, blank part, chippings, environment) on the temperature. The simulation is carried out on the basis of joint solution of thermal conductivity differential equations written for each interacting object. To calculate equations, the authors used the finite-elements method. The authors developed the methods and the software for temperature field calculation. The article gives the results of numerical simulation of temperatures by low vibration amplitudes slightly changing micro-cutting kinematics. By ultrasonic vibrations, the blank part temperature was by 10% lower, and the local temperatures in the zone of contact of abrasive grain with the blank part and the chippings was by 14% and 15% lower correspondingly.

Frontier Materials & Technologies. 2015;2(2):191-195
pages 191-195 views

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