Metalloobrabotka № 3 (87)/2015

Processing Of Materials By Cutting

Khanov A. M., Muratov K. R., Gashev E. A. Lapping of siliconized graphite end seals

Presented raster method abrasive treatment of precision flat surfaces of details, as well as lapping machine with raster kinematics of the tool. Formulate general engineering and design guidelines that must be followed in the development of device for lapping on machine tools with raster tool kinematics. For pieces of brittle composite material based on graphite, we have designed and manufactured a universal multipiece arrangement. The device allows to compensate for different height of processable workpieces, to provide for their self-aligning on the tool surface, and to place the pieces evenly over the surface of lapping. The experimental testing of the treatment process on the machines with raster kinematics of the tool working movement was carried out. The comprehensive studies of precision treatment process for high-precision pieces made of composite materials based on siliconized graphite GAKK 55/40 were conducted. The requirements for working planes of the pieces are the following: Ra not more than 0,1 μm, flatness deviation not more than 0,6 μm.

Keywords: raster processing method, precision of geometric shape, surface grit, siliconized graphite, Rastr-220.

Kryukov A.A. Technology of hardening of long cylindrical products by joint tension and reversing torsion

A study of the technology of hardening of long cylindrical products involving the establishment in the nearsurface region of the article favorable compressive residual stresses due to successive stretching elastic-plastic deformation first, and then, when fixing the resulting tensile longitudinal strain, torsion. Instead, the existing regimes of hardening comprising a single twisted article in a state of tension, developed new modes consisting in reverse twisted articles in a state of tension. Developed new technological modes provide optimal distribution of ьresidual axial stress over the cross section of the product at the minimum value of the residual shear stresses. Such a distribution of residual stress improves the fatigue strength of the product. As a result of the corrosion-fatigue tests proved highly effective technology hardening joint tension and reversing torsion.

Keywords: a joint tension and torsion, alternating torsion, residual stresses, elastoplastic deformation, corrosion-fatigue tests, fatigue strength, cyclic durability, the technology of hardening.

Shafranov A. V., Kobityansky A. E., Smyshliaeva T. V. Mathematical models of the dynamics of the spindle unit for the process surface grinding

The paper presents a mathematical model of the dynamics of the spindle assembly for surface grinding process. It is shown that mathematical modeling of dynamic processes spindles, which allows to identify and numerically evaluate the most important factors affecting the accuracy of machining. In the process of modeling the functioning of the features of the machine spindles model 3V642. The analysis of the impact of structural and technological parameters on the spectral and vibration characteristics of the elements spindles.

Keywords: spindle assemblies, mathematical model, dynamics, composite model.

Electrophysical And Electrochemical Processing Methods

Khanov A. M., Ablyaz T. R. Regression analysis process wire cut EDM packaged blanks

The aim is to conduct a regression analysis of Wire EDM of packaged blanks and obtaining models capable of predicting performance surface quality, depending on the processing conditions. Based on the analysis obtained empirical model establishes the relationship between the terms of Wire EDM performance and surface quality.

Keywords: EDM, the electrode-tool accuracy, roughness error.

Kilina P. N., Drozdov A. A., Sirotenko L. D. Formation samples with cellular structures by selective laser sintering of metal powders

The aim is to study the effect of different intensities of laser radiation on the process of selective laser sintering and to obtain samples with cellular structure of various metal powders (steel, titanium and tungsten). The possibility of the creation of cellular materials with complex spatial structure by selective laser sintering. With the help of software Delcam PowerShape were created 3D-models of samples having a cellular structure. The powder particles were sintered to the steel and titanium substrates at various parameters of the laser radiation. Obtained steel, titanium and tungsten samples with cellular structure.

Keywords: highly porous cellular materials, selective laser sintering, powder, laser quality.

Morozov E. A. Coatings investigation of alloy steel obtained by laser cladding

The investigations cover of stainless steel, obtained by laser welding. The material is welded steel — H13, substrate material - steel 10. The influence of technological parameters of laser cladding on the thickness and porosity of the coating was study. By full factorial experiment obtained empirical dependence of the thickness of the coating on the laser power, scanning speed and flow of the powder material. The resulting coefficients of the regression equation are specific to the studied material, but the influence of process parameters on the resulting laser cladding coating characteristic of other materials.

Keywords: laser welding, regression analysis, porosity.

Oglezneva S. A., Porozova S. E., Ogleznev N. D., Gilev V. G.,Torsunov M. F. Research cooperation in the powder materials of the copper-carbon phase for the electrodes-instrument

The aim was to study the formation of the structure of carbon phases — colloidal graphite, expanded graphite and carbon nanotubes — during sintering with copper and the establishment of dependence of the relative wear of the electrode-tool during EDM firmware on its composition. Composite materials based on copper with different contents of carbon phases are made by powder metallurgy. X-ray diffraction and Raman spectroscopy analysis and revealed the formation of intercalated graphite and copper sp3 bonds in graphite, sintered copper that enhance conductivity and capillary properties of the material. In piercing tool steel on draft mode found that erosive wear electrode-tool system "copper-colloidal graphite" 8–5 times less than that of copper, and of the "copper-tungsten." An explanation of the electrode wear "copper-graphite."

Keywords: electro-discharge machining, tool electrode, composite material, Raman spectroscopy, intercalation, copper, graphite, carbon nanotubes, erosion resistance

New Materials And Production

Bogomyagkov A. V., Pustovalov D. O., Sharov K. V. Research melt flow in step and ringshaped gating systems with different cross-section feeders

The paper proposes a method of research of step gating systems, concluding of theoretical calculation, numerical modeling and experimental investigation on a laboratory stand. Theoretical calculation founded on Bernoulli equation and continuity equation. Produced initial modeling pouring process of laboratory stand using the program complex «ProCast». Laboratory bench poured with a model fluid. Water was selected as a model liquid. Compliance of theoretical and experimental data is obtained.

Keywords: sprue, collector, step gating system, ringshaped gating system, liquid flow rate, modeling, ProCast.

Karavaev D. M., Nesterov A. A., Matygullina E. V., Smirnov D. V., Isaev O. Y. Perspectives of reduce the cost of metalworking ball valves, operating at temperatures above 200 °C

The work presents a comparative analysis of the structures of ball taps with the demands placed on them operational requirements.. The authors of the material of the saddle seal ball tap provides a composite material based on expanded graphite and a modified silicone resin having increased elasticity, low friction and high wear resistance. The results of the test samples of composite material molded by one-sided molding. Use of the ball taps with saddle seals made from this composite will expand operating temperature range of ball taps on a "metal to the polymer" to 550 °C and significantly reduce the cost of

the finished product.

Keywords: close fitting valve, ball tap, composite material, expanded graphite, polymer, precision, mechanical processing.

Shumkov A. A., Ablyaz T. R. Experimental determination of deformation of the molding surfaces of the

master - models for layer-by-layer synthesis of photopolymer material

The possibility of determining the surface strain rp-prototypes fabricated layer-by-layer synthesis of photopolymer material. During the simulated and the obtained samples with monolithic and internal regulated cellular structure. Using 3-coordinate measuring machines defined axial displacement of the sample surface at different points of the cross section. According to the measurements used to construct three-dimensional graphics display area direction strain in the sample with a solid and cellular structure. It is established that the presence in the sample of internal adjustable cellular structure determines the change of the direction of deformation.

Keywords: rp-prototype, layer-by-layer synthesis, cellular structure, casting of cutting patterns.

Strukov N. N., Smetkin A. A. The deveiopment of carbontitanium composite materials for medical implants with the use of surfacing technology

Experimental samples of composite material based on titanium and carbon were obtained by the welding technique. It is shown that when surfacing titanium on carbon is formed an intermediate layer containing a solid solution of carbon in titanium and titanium carbides of various types. The estimation of the structural parameters on the basis of electron microscopy studies. The resulting material is promising in the manufacture of medical implants.

Keywords: composite material, titanium, carbon, surfacing, structure.