The authors developed the design of a special multi-blade rotary-friction tool. The multi-blade rotary-friction tool is equipped with two cupped cutters – heating and cutting. The heating cupped cutter is made of medium-carbon structural steel of any brand, and the cutting cupped cutter is made of steel R6M5. The final formation of the treated surface and its quality is provided by the cutting cupped cutter. This article presents the results of the calculation of the strength of the cutting cupped cutter multi-blade rotary friction tool. As a result, the following were established: when processing steels 30HGSA cutting force components reach the maximum value than when processing materials 40HN2MA, St.45, and St.3c (calm); strength and rigidity of the cutting cupped cutter is sufficient for processing optimal cutting conditions: nsp = 1000 rpm; S = 0.42 mm / rot; t = 1.0 mm.
The authors developed a special design of a rotary friction tool with a self-rotating cup cutter for rotary friction boring of large holes. This paper presents the results of parametric optimization of stressed components of the rotary friction tool by virtual experiments in ANSYS WB. The authors predicted the cutting force components at the worst position of the cup cutter, which was 20 degrees as contact forces in the process of boring a large diameter hole, and built a design model. Using the Johnson-Cook model as the failure criterion for the elements of the mesh, projections of the cutting forces resulting from the hole processing were obtained. The relation between input and output parameters (stresses) is established, optimization criteria are specified, and optimal parameters of the tool stresses components are chosen. It was also found that the averaged values of the force at the initial moment (cutting into the workpiece) change linearly, then becoming practically constant. The idea of parametric optimization consisted in carrying out several virtual experiments, in which the possible range of variation of the basic dimensions was indicated and the optimization criteria were set, the optimal parameters of the tool design were selected from the presented candidates. The optimization method bypasses the design cycle, which is costly and time-consuming due to prototype testing and subsequent refinement.
The This article deals with the replacement of the magnetic grippers on the VPO-3-3000 machines with roller grippers. The novelty lies in the establishment of dependences characterizing stress and strain in the elements of the lifting and straightening devices and in the rails during the operation. Reliability of the program for calculating the structural parameters of the lifting and straightening device for the VPO-3-3000 track renewal machine is shown. The developed design of the lifting and straightening device makes it possible to select the rational parameters of the technology and the operating mode of the device. It This design is recommended to for use it when developing working bodies for the straightening machines. The article presents the calculation of the lifting and straightening device structural elements' strength during its operation, in the Ansys WB software package.
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