This article presents ANSYS WB-based mathematical modelling of the thermofrictional milling process, which allowed studying the dynamics of thermal and physical processes occurring during the processing. The technique used also allows determination of the optimal cutting conditions of thermofrictional milling for processing various materials, in particular steel 40CN2MA, 30CGSA, 45, 3sp. In our study, from among a number of existing models of cutting fracture, we chose the criterion first proposed by prof. V. L. Kolmogorov. In order to increase the calculations performance, a mathematical model was proposed, that used only two objects: a parallelepiped-shaped workpiece and a cutting insert in the form of a pentagonal prism. In addition, the work takes into account the friction coefficient between a cutting insert and a workpiece taken equal to 0.4 mm. To determine the temperature in the subcontact layer of the workpiece, we introduced the coordinates of nine characteristic points with the same interval in the local coordinate system. As a result, the temperature values were obtained for different materials at the studied points during the cutter speed change. The research results showed the possibility of controlling thermal processes during processing by choosing the optimum cutting modes.
When producing large-dimensional parts of heavy machines, the largest specific weight in the general labour input is made by the operations, connected with machining the main holes, i. e. holes of large diameter. To the holes of large diameter of large-dimensional parts, there are specified high requirements in the aspect of accuracy of the size, shape and arrangement. Machining of holes still remains one of the topical problems of present day mechanical engineering, in particular machine-building enterprises of the Republic of Kazakhstan.Solving the problem of ensuring accuracy and quality of machining large holes of large-dimensional parts requires the development of new resource-saving technologies of machining. In this work there are presented the results of studying a resource-saving method of rotation-friction boring of large diameter holes. There has been achieved good results in providing the quality indicators, when machining by the proposed method of rotation-friction boring with the use of the tool (a disk cutter) made of steel 90CrSi5 in comparison with well-known boring of holes. The diagram of chip formation of cutting and the results of studying the zone of chip formation by the metallographic method is also presented.
This article presents the experimental study results of the process of rotational friction holes boring using a cup cutter surfaced by STOODY M7-G material. As a result of experimental studies, the following quality indicators were achieved: surface roughness within Ra=10÷1,25 micrometer; surface hardness within HB 212-248. Using a cup cutter surfaced by STOODY M7-G material in case of rotational friction boring of large-diameter holes for large-sized parts can improve processing performance in comparison with cutting tools equipped with hard metal plates and provided the required surface roughness. Preliminary calculations showed that the manufacture of cup cutters from non-instrumental materials reduces the cost of the cutting tool by 5-7 times and the cost of the operation by 1.5-2 times.
This article deals with replacement of the magnetic grippers on the VPO-3-3000 machines with roller grippers. The novelty lies in establishment of dependences characterizing stress and strain in elements of the lifting and straightening devices and in 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 technology and the operating mode of the device. This design is recommended for use when developing working bodies for the straightening machines. The article presents calculation of the lifting and straightening device structural elements' strength during operation, in the Ansys WB software package.
The article proposes the solution of the problem with the application of thermal vibrations of heat-carrier flow in processes of convective drying, for the purpose of theoretical determination of optimum conditions of short-term excess of handling temperature, that do not influence the decrease of technological characteristics of the thermosensitive materials.
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