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scientific edition of Bauman MSTU

SCIENCE & EDUCATION

Bauman Moscow State Technical University.   El № FS 77 - 48211.   ISSN 1994-0408

Constructional Material Processing in Machine Building

Challenging Issues for Predicting and Validating Reliability of Sustained Spacecraft Operation
# 06, June 2015
DOI: 10.7463/0615.0778993
V.F. Alyoshin, A.Yu. Kolobov, J.A. Petrov
pp. 31-41
Influence of the Ion Treatment Regime on Defects Density and Surface Destruction of the Polycrystalline Glass
# 12, December 2014
DOI: 10.7463/1214.0748236
D.V. Duhopel'nikov, S.G. Ivakhnenko, E.V. Vorob'ev, A.A. Azerbaev
pp. 181-191
Formation of Quenching Structures in the Steel 35 by Deform Cutting
# 09, September 2014
DOI: 10.7463/0914.0725672
A.G. Degtyareva, V.V. Poptsov, V.N. Simonov, V.G. Vasilev, S.B. Varlamova
pp.30-44
Parameterization of Mechanical Process Operations Taking into Consideration a Coefficient of Variation and Tool Life
# 06, June 2014
DOI: 10.7463/0614.0714287
A.S. Sgibnev, P.V. Kruglov
This article describes the results of studies on methods for increasing the reliability of  mechanical process operations of hard-to-machine materials . Technological system is treated as a combination of factors affecting the treatment process. The article estimates an impact of factors such as a choice of the tool material, applied technology environment, processing modes on the reliability of technological operations. For different workpiece materials ( steel and corrosion resistant alloys, tungsten, etc. ) it describes the conditions under which tool life increases and a coefficient of variation reduces.
Self-Healing Structural Properties of Thermoplastics in HF Field
# 06, June 2014
DOI: 10.7463/0614.0713624
N.G. Filippenko
The last decades are characterized by growing production of polymer materials and using their products in all industries. Despite the declared warranty service, a number of products from polyamide materials are rejected in the course of their operation before a baseline period normalized by the manufacturer expires. Therefore, one of the possible ways for safe operation of polymer products is their self-healing. This is especially true for products from polymer materials exploited in hard-to-reach areas and machine and mechanism units. In this regard, the aim of this study was to develop an algorithm that enables the self-regeneration of the mechanical properties of polymer materials. To achieve this goal, the authors identified the following problems: defining the methods to provide self-healing of polymer materials, reasoning the possibility to detect damage in products from polymer materials, creating the algorithm to form a signal initiating the recovery process, defining the efficiency to regenerate the material. The paper discusses the problems of determining the conditions for the self-healing of polymer material structure. For finding the ways to determine the fatigue failures, methods of their determination proposed and developed by authors are used taking into account the real-meteorological and climatic operation conditions by the example of the products of the rolling stock of Russian Railways JSC. Using the samples of glass-nylon composite the necessary and sufficient indicators to determine the strength characteristics of the studied materials are found. The algorithm of self-healing is developed and experimental ratios to characterize a recovery of polymer materials are obtained.
High-Frequency Electro-Thermal Processing of Secondary Non-Metallic Raw Materials
# 06, June 2014
DOI: 10.7463/0614.0712029
A.V. Livshits, N.G. Filippenko, A.N. Larchenko, S.N. Filatova
The article aims to give a physical representation of the electro-thermal equipment operation to enhance its application capabilities in recycling the secondary raw material and describes a number of electrothermics technology applications in this area. The article presents a comparative analysis of the results of the high-frequency and microwave heating. As an example of wastes recycling of the forestry and woodworking industry, is shown an efficient use of high-frequency equipment in the technological processes of drying. The article offers the technological tooling developed by authors for forming the fuel briquettes. This technological equipment allows the use of thermo-mechanical method of their drying. The article describes experimental research results of waste processing of oil-petrol-resistant flexible PVC, cooking fuel briquettes, and facing materials from sawdust, which use a modifying additive as a crumb from the polyethylene waste, thereby increasing the durability of fuel briquettes, warmth, and stability of its combustion. Results of done work have shown the prospects for using the RF power to process the wastes of wood, plastic, and oil-petrol-resistant PVC.
The Provement of the Conditions of End Mill Operation in External Panels of the Aluminum Alloys
# 05, May 2014
DOI: 10.7463/0514.0709770
S.V. Grubyy, A.M. Zaicev
We have worked out the calculation procedure of cutting force and contact pressures between the back surface of tool tooth and aluminum alloy component used for mill operation with end-milling cutter. This force calculation includes the aluminum alloy softening under the impact of cutting temperature. The calculated force figures and figures of contact pressures on the back surface of tool tooth are used for evaluation of the bottom strain and deformation appearing while digging and pocket mill operation inside the external panel of aluminum alloy. The cutting techniques and mill operation conditions have been also approved. The testing of the research results held within the processing the mill operation technologies of the external panels in manu-facturing environment has also been carried out
Plasma Powder Coating of Rods of Hydraulic Cylinders with White Wear Resistance Cast Iron
# 05, May 2014
DOI: 10.7463/0514.0709302
S.P. Nefedyev, A.N. Morozov
The article considers the features to form a structure and properties of Fe-C-Cr-V system coverings provided by the plasma and powder coating on the low carbon steel. It is shown that it is possible to restore a rod of hydraulic cylinders of small diameter by the plasma and powder coating. Thus, to avoid buckling and provide the built-up metal structure with the best wear resistance it is necessary to find a reasonable approach to a choice of the operation conditions to provide coating. The paper offers a way for efficient control of heat input at coating and a superheat value of the welding bath.  It is noted that the coverings, which have been built up at the smallest heat input in a substrate, possess the best wear resistance, with a fusion zone formed with an austenitic crystallization interlayer.
Unbalanced Heat Isolation in High-Frequency Electrothermics of Polymers
# 05, May 2014
DOI: 10.7463/0514.0709325
A.V. Livshits
The article describes a mathematical simulation of high frequency (HF) electrothermic of thermoplastics to be applied to a technological system in the form of the five-layer plate, including electrodes, insulators, processed material and studies the influence of heat insulation on the thermoplastic heating. The article presents a mathematical model in the form of a system of nonstationary heat transfer considering the internal heat sources with different boundary conditions and the software to implement it. The software offered in the article enables to study the mutual influence of geometrical and electro-physical parameters of technological systems of HF thermoplastic heating. Based on the calculations presented in numerical and graphic form, the following areas of heating polymer are identified: uniform heating, regional zones of thermal influence of insulators. The article provides the research results of influence of different thickness heat insulation on the distribution of temperature field of thermoplastic. It is determined that one can shift the zone of maximum heating polymer modifying the parameters of insulating layers, thus allowing to improve the welding quality of polymeric items. According to research results, the conclusion has been drawn up that it is desirable to develop a technological process of electro-thermal welding of polymers with the possibility for displacement of the zone of maximum heating (melting) polymer due to changing heat insulation thickness. The developed software allows a new approach to study the HF-heating modes and  have solution of practical tasks for improving the quality of welded joints of parts from thermoplastics.
Developing a Mathematical Model of the Tooth Profile Angles of Thread Milling Cutter With Helical Flutes
# 04, April 2014
DOI: 10.7463/0414.0707227
O.V. Malkov, L.D. Mal'kova
Based on the developed geometrical model an experiment is conducted to calculate the values of tooth profile angles of thread milling cutter with helical flutes at variation of five factors in the established factorial space. When planning the experiment the full central composite draft has been elaborated in the coded form for five factors at three levels taking into account the orthogonality and the impossibility to conduct repeatedly experiments in the chosen points. Mathematical models are developed to calculate the tooth profile angles of thread milling cutter with helical flutes allowing to obtain the values of angles depending on a pitch of thread, a cutter diameter, a rake angle, an angle of lead of helical flutes, and a back angle. Calculation of the profile angles made according to polynoms for all combinations of factors has shown that an error of calculated values in comparison with the values obtained using a geometrical model do not exceed a tolerance for a half of tooth profile angle according to GOST 1336-77.
Design and research of calculation models of the tooth profile angles of thread milling cutter with helical flutes
# 03, March 2014
DOI: 10.7463/0314.0702743
O.V. Malkov
The paper presents a developed in CATIA V5 R17 software geometric model, allowing to determine the angles of the tooth profile of thread milling cutter with helical flutes. The model research has been conducted for geometric and design parameters of thread milling cutter, made of cemented carbide and high speed steel. It is established that available rake and clearance angles, and inclination angle of helical flutes at the accepted values of pitch and diameter of the tool lead to obtaining the angles of the tooth profile other than 30 degrees, thus requiring the calculation of angles β1 and β2 in each case of design. In the general case we have an asymmetrical profile with respect to the axis passing through the top of the tooth. The influence of geometrical and design parameters of the model on the values calculated angles is established.
On deformation of thin-walled parts while turning on the lathes
# 02, February 2014
DOI: 10.7463/0214.0700319
E.V. Arbuzov, A.D. Zhargalova, G.P. Lazarenro, V.I. Semisalov
The paper studies the overall picture of deformation of thin-walled parts while turning them on the lathes. Its objective is to define configuration and value of the process-induced deformations under turning conditions of mechanical engineering. The paper investigates the parts of class “tube” and “disk”. A solution of the problem under consideration uses computer simulation in ANSYS software environment. The study task is to estimate the prospects for concept development to machine the thin-walled parts with controlled deformation under “soft” turning conditions. The simulation has shown that the change of turning conditions within the studied intervals causes changing deformations of parts in the range from 0.1 to 3 values of tolerance zone. This result can be a basis to plan further activities in the field concerned.
Experimental Setup for Diamond Grinding Using Electrochemical In-Process Controlled Dressing (ECD) of Grinding Wheel
# 03, March 2014
DOI: 10.7463/0314.0699920
M.A. Shavva, E.M. Zaharevich
The paper considers basic methods and types to make dressing of diamond grinding wheels. It presents a classification of methods according to different criteria, analyses the positive and negative aspects of using the existing types of dressing and current trends in this area. The paper presents description both of Electrochemical In-Process Controlled Dressing (ECD) and of Electrolytic In-Process Dressing (ELID). Further, it describes the experimental setup for Electrochemical In-Process Controlled Dressing, its scheme, the model and the main process parameters. It also reveals a set-up design technique, its application analysis, and describes parameters of ECD-process control.
Process modeling and ultra-precision machining technology development for flat reflectors using a diamond milling head
# 02, February 2014
DOI: 10.7463/0214.0699743
S.V. Grubyy, V.V. Lapshin
The article describes a discontinuous process to machine flat aluminum alloy reflectors using a milling head equipped with a single-point diamond cutter. A developed technology allows machining the parts of optical surface quality. The article analyses the kinematic scheme and presents the model to calculate the cutting forces and temperatures. It also offers schemes to determine the cutting length when machining the flat reflector. The proposed model-based data have been compared with the experimental study data from various sources. The experimentation part represents the flat reflector machining results achieved owing to developed technology. The tests have confirmed the technology effectiveness. The ways to improve the quality of machining have been outlined.
Analysis of indirectly measured cutting forces in turning metallic cylinder shells
# 02, February 2014
DOI: 10.7463/0214.0687971
K.E. Kondratenko, A.M. Guskov, M.A. Guskov, Ph. Lorong, G.Ya. Panovko
Measurement of cutting forces is an important component for development and validation of manufacturing processes. To use generally accepted direct measurement systems available for this purpose is often impossible. This paper suggests an indirect method to estimate the cutting force when turning a thin-walled cylindrical shell. The method is based on the displacement measurements of the flexible workpiece. Furthermore, when it comes to the flexible workpieces turning, cylindrical shells in particular, there is a need to use non-contact displacement sensors. This paper considers a specific manufacturing system in which two radial displacement sensors are located close to the free end of a cylindrical shell, the opposite end of which is rigidly fixed in a chunk of a lathe. Measuring the radial and the circumferential components of the cutting force is under study. The model has been developed in a quasi-static approximation. An experimental case has been analyzed using the proposed method. Optimization of the angular location of two displacement sensors has been proposed based on the idea of minimizing the condition number of the linear transformation matrix.
 
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