Nº 8 (146) (2023)
Technologies of mechanical processing of workpieces
COMPUTER SIMULATION TECHNIQUE FOR DRILLING PROCESS OF TITANIUM ALLOY AND COMPOSITE MATERIAL COMPLEX PACKAGES USING DIGITAL TWINS
Resumo
Complex packages of polycrystalline composite materials based on carbon fiber plastics and titanium alloys find wide ap-plication in the designs of machine-building products and become the main material in the production of high-speed modern transport modes. However, the technology of machining parts surfaces made of these materials, namely holes, is character-ized by insufficient knowledge, lack of standards for cutting modes and is based more often on the production experience of enterprises. When machining conditions and materials of complex packages change, the duration of technological prepara-tion of production causes a significant increase in the cost of manufacturing components and parts due to the need for com-petent selection of rational elements of the cutting mode. To exclude the empirical fit of rational elements of the cutting mode on machining facility, the possibility of using digital twins of drilling processes in workpieces made of these materials is studied. It also implies the introduction of ultrasonic field energy into new surfaces generation of geometry in order to improve the quality of the machining area production efficiency and reduction of technological preparation of production based on the selection of elements of the cutting mode instead of testing the selected machining conditions using the existing technological equipment. The LS-DYNA program was used in the simulation process. Preparation of models and data pro-cess was carried out in the LS-Prepost 4.8 program. In the course of research, an explicit simulation technique with pre-liminary validation was used. Studies proved that the developed finite element models allow simulating the technological processes of simultaneous drilling of packages of titanium alloy and composite material in a computer (digital twin) without conducting sufficiently complex and costly field tests. Generated by simulation, a calculation sheet was obtained containing the simulation process, the solution of which visually reflects the process of drilling holes in workpieces made of complex packages of titanium alloy and composite material, as close as possible to the real situation with chip removal. Since the use of digital twins for performing this stage of technological preparation of production in the conditions of existing enterprises is not associated with a long and expensive operation of machine-tool fleet, we should expect a significant reduction in the cost of manufacturing components and parts from similar materials in industry, primarily in small-scale or single-part pro-duction.
3-11
DESIGN OF MECHATRONIC SYSTEMS OF HYBRID MACHINE COMPLEXES
Resumo
The world trends over the last half century and prospects for the development of technological equipment complexes for the coming decades are viewed. A comprehensive analysis of the applied stages and stages of designing processing machinery with the help of the construction of traditional mechanical design models is carried out. It is shown that the prospects of using energy flows to intensify machining processes should be analyzed at the early stages of design, using thermal and elec-trophysical criteria to study the emerging connections in the system. It is proposed to start designing mechatronic systems of machine complexes by analyzing structural connections of information technologies in hybrid production, including tradi-tional and additive technologies. It is recommended to use sequences of transfer criteria to analyze the processes of for-mation of material structures and the surface layer under thermomechanical and electrophysical processing. The criteria of heat and mass transfer sequence the structure formation in the finished material with an increase in the power of stimula-tion. The criteria characterizing energy flows within electrophysical processing influence the sequence of surface phenome-na and determine the process of material properties formation. Feedbacks linkage in the control of production machinery is shown through the degrees of tool freedom, particles of the applied material and the layer to be removed, by means of addi-tional effects of energy flows. Taking into account direct and feedback loops in the technological system, numerical control systems should be selected and the machining facility complex should be designed as a mechatronic system. The complex of hybrid technological equipment from the standpoint of computerization of production activities, as well as its modules, should be designed as computer peripherals devices based on the same architecture like a computer.
12-19
Technologies of electromachining and combined processing
AUTOMATION AND DIGITALIZATION OF ULTRASONIC TECHNOLOGICAL PROCESSES
Resumo
Having analyzed the literature sources, it is revealed that digital production includes not only full automation of production processes, but also the creation of a multi-level infrastructure for their control on the basis of information technologies. Technical solutions based on this approach will significantly intensify production processes. The possibilities of automation and digitalization of ultrasonic technological processes are viewed through the creation of a hardware and software com-plex that includes technological and measuring equipment, as well as software to select the most effective technical solu-tions. Some general principles of creating ultrasonic technologies are substantiated, their stages of development include setting the task, analysis of the processing object, selection of the processing scheme and equipment, process control and quality monitoring. Methodological approaches to the implementation of production processes with a multi-level process control infrastructure based on information technologies are proposed. Examples of developed software products are given, with the help of which search engine optimization methods are used to select equipment and rational processing modes. It shows not only the possibility of using automated technology, but also the creation of a self-learning technological system based on it. The development and creation of equipment for the implementation of the proposed technical solutions has in its basis general principles of using numerical control software. The proposed algorithm can be used for a wide range of ultra-sonic technologies: cleaning, surface plastic deformation, coating, cutting, etc. In addition, the combination of the choice of technical and information solutions makes quick switch from one type of processing to another possible. Recommendations on the implementation of the proposed technical and information solutions are given.
20-26
COMBINED TECHNOLOGIES FOR INCREASING THE RELIABILITY AND SERVICE LIFE OF AEROSPACE PRODUCTS
Resumo
The paper considers a major scientific and applied problem of improving the quality and reliability of scientific products by technological methods and means, forming the basis for the production of competitive products of domestic engineering, primarily in the aerospace industry. The analysis of the defect appearance causes in technology and the decrease in its reli-ability at the stages of product life cycle is carried out. Measures were identified to ensure established reliability while maintaining or increasing the resource with minimizing costs at the stage of commercializing by gradually increasing opera-tional characteristics underway product test. It is shown that combined methods of part process allow creating small-sized multilayer vibration-resistant filters with an increased area of the working area and a total wall thickness that ensures the stability of the product to repeated vibrations, which previously caused undesirable increase in the dimensions and mass of a manufactured product. The possibilities of using combined processing methods with the imposition of electromagnetic fields to improve the operational characteristics of upgraded and aircraft parts under formation, including their elements, in the expansion of mass production of scientific products, particularly developed for their import substitution, are found.The change in the mechanical characteristics of materials under various processing methods has been studied. Specimens test for strength at failure and stretch have shown that the consistent use of highly efficient electrochemical sizing followed by jackhammering (or other) way of hardening allows the increase in the characteristics of products up to 10%, achieving a result not lower than that obtained after tooling with hardening.
27-34
Technological support of operational properties of machine parts and their connections
ENGINEERING SUPPORT FOR THE MANUFACTURE OF GEARS OF AVIATION GAS TURBINE ENGINES PROVIDING FOR THE INSTABILITY OF THE PHYSICAL AND MECHANICAL PROPERTIES OF THEIR MATERIALS
Resumo
The key place in the production of gas turbine engines, including gears, both aviation and marine, also power generation turbines, is given to sectional steels. Consequently, not just a physical nature of gear wheels manufacture plays an im-portant part, but formal characterization and the supply of physical and mechanical properties of materials are in the prior-ity, taking into account the reliability of the materials. The problem of technological support for the manufacture of gears for gas turbine engines is viewed with simultaneous analysis of the part material, its manufacturing technology and investi-gated inseparably from each other. The interrelation of working surfaces quality and technological and strength character-istics with respect to operational properties is developed. The instability of the mechanical properties of the structural ma-terial is investigated and their formation is justified on the basis of technological heredity in accordance with the techno-logical process of manufacturing a part to its material and purpose. The instability of physical and mechanical properties is clearly presented on the example of one steel grade, but with different methods of obtaining the workpiece and the material in as-received condition. The influence of heat treatment on the stabilization of the physical and mechanical properties of the material, taking into account the inheritance of properties, is studied. A model of the contact interaction of gears has been developed taking into account external and internal influences, both during preparation and under operation (materi-al properties, engagement forces, temperature field, etc.). The cumulative model, focused on the reaction of the structural material in machining and interaction in work, summarizes a functional use, physical and mechanical properties and fea-tures of behavior in operating conditions. The control of the operational properties of gears is presented in an inseparable connection with technology and their materials such as structural state and physical and mechanical properties.
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MACHINE-BUILDING LINE OF PRODUCTION
Resumo
Specialization types such as subject, technological, their levels and areas of their effective application are viewed. Since any specialized production is aimed at running-out production, so subject specialization is primary, for example, in the produc-tion of automobiles, as for technological specialization, it is secondary, for it shows a technological method to allow making a product, for example, in the foundry production. The level of subject specialization and the level of technological special-ization should dovetail into one another. It is shown that the types of production (unit, full-scale, mass) are based on the cor-responding levels of subject and technological specialization, the lower the level of subject specialization, the lower the level of technological specialization. For example, small volume manufacturing is due to a low level of subject specializa-tion. An increase in the level of subject specialization results in the level increase in technological specialization - manufac-turing production process management, etc. Subject-specific specialized production can be divided into two groups: the first group includes the production of products that meet human needs, for example, vehicles and means of their engineering sup-port, for example, machine tools. The second group includes specialized production of their elements (assemblies, parts), for example, pumps, motors, screws, nuts, etc. The problem of specialized production management of products related to the sec-ond group is the lack of complete information about their design diversity and frequency of application. To solve the prob-lem, it is proposed to consider the products of the second group in a modular representation, which allows all their diversity to be divided into two groups: functional technological modules (FTM) that ensure the performance of a product's function-al purpose and functional service modules (FSM) that ensure (FTM) functioning. On this basis, a systematic approach ap-plicable for specialized production management for products of the second group, is given It is shown that for the implemen-tation of the proposed system approach in the specialized production management for the products of the second group, it is necessary to build a database of two types: FTM database and the FSM database.
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