Metalworking № 1 (151)/2026

MATERIAL CUTTING

Golovkin P. A. On the issue of the quality of ground blanks for the manufacture of electric vacuum devices

The reasons for the failure of polished blanks made of molybdenum alloys intended for the manufacture of electric vacuum devices are analyzed. It is shown that the reason for the defect of blanks on the basis of surface defects exceeding the tolerance limits is the deterioration of the manufacturing technology of the initial wire. Namely, in order to reduce costs, manufacturers are abandoning the circle-oval-circle broaching scheme in favor of the circle-circle-circle scheme, and at the same time increase the amount of one-time compression. Based on the analysis of the technology, the systemic causes of fluctuations in the quality of workpieces depending on their diameter are revealed.

Keywords: molybdenum alloys, drawing, wire, defects, cut-to-length blanks, grinding, vacuum density, electrovacuum devices

Rumyantsev V. R., Denisov M. A., Vasilkov D. V., Nikitin A. V. Investigation of force interaction during contour milling of the profile of the working part of turbine blades

A study of the force interaction during contour stitch milling with end mills of the profile of the working part of turbine blades has been performed. The main problem of modeling is considered and solved, which consists in the fact that metal is sequentially removed during processing. There is a change in the elastic characteristics of the workpiece and the conditions of force interaction. Taking into account the material removed by the previous lines, the thickness and width of the cut, as well as the contact spot in the cutting area, are determined. The obtained ratios of cutting forces during processing in solid metal and in the wake of the previous stroke. A study of deformation in the bending and torsional subsystem of the workpiece has been performed, taking into account the main axes of stiffness in cross sections. The conditions for ensuring dimensional accuracy and surface roughness are obtained. The performed complex of studies made it possible to determine the cutting forces during contour stitch milling with end mills of the profile of the working part of the turbine blades, taking into account the allowance taken on the previous lines, as well as to obtain technological modes and processing conditions that ensure dimensional accuracy and surface roughness in accordance with technological requirements.

Keywords: contour stitch milling, end mills, turbine blade, profile of the working part, cutting forces, dimensional accuracy, surface roughness

ELECTROPHYSICAL AND ELECTROCHEMICAL PROCESSING METHODS

Asaev A. S., Averin N. V., Sitnikov I. V., Murog I. A., Raev S. I. A method of combined electrochemical and abrasive polishing using the cavitation effect of polycomponent media

This paper proposes a new method for combined electrochemical and abrasive polishing using the cavitation effect of multicomponent media. Experimental data on the machining of 12Kh18N10T steel and AMg6 alloy samples are presented. The quality and productivity of the surface treatment of the test samples using the proposed method are determined. Areas of practical application for machining metals and alloys using this method are identified.

Keywords: non-stationary electrolysis, combined processing, cavitation

NEW MATERIALS AND TECHNOLOGY

Molchanov R. A., Oborin A. V., Porsev K. I. Analysis of modern research methods and technologies in the development of clamping fixtures

This article presents an overview of existing methods for researching clamping fixtures, ensuring their effective development and application in modern manufacturing environments. Key features of these research methods are discussed, with special attention given to the integration of traditional methods and digital manufacturing tools. This study is based on a comprehensive analysis that highlights key modern trends in clamping fixture design.

Keywords: machine tools, research methods, digital tools, finite element method, CAE systems

Smagin E. V., Efremov A. K. Restoration of heat exchanger serviceability by plugging tubes and tube sheet holes

This paper provides an analytical review of the designs and application technologies of plugging devices for restoring the serviceability of shell-and-tube heat exchangers and air-cooled heat exchangers. The causes of defects in tube bundles and the evolution of plugging methods—from simple tapered plugs to modern high-pressure mechanical systems (such as Pop-A-Plug, T_APPL, Torq N’ Seal)— are considered. Particular attention is paid to the comparative analysis of domestic and foreign developments, their advantages, disadvantages, and application areas. The key technological requirements for plug installation, mandated by the new national standard GOST R 71709-2024, are presented.

Keywords: heat exchanger, tube leak-tightness, plug, heat exchanger repair, tube plugging technology

MACHINES AND EQUIPMENT

Shashurin A. E., Krutova V. A., Raschupkina T. V. Derivation of the energy conservation equation taking into internal losses in bar structures using the example of high-capacity overhead cranes

On the example of a high-capacity overhead crane, a derivation of the energy conservation equation is given, taking into internal losses arising in the bar structure. Considering that crane frames are made of channels, the acoustic source is assumed to be a linear radiator, and the frame is represented as an energetically closed bar structure. The article presents a study of the influence of internal losses on the distribution of sound vibration energy using the example of an overhead crane.

Keywords: noise, vibration, loss factors, overhead cranes, energy methods

THE ORGANIZATION AND MANAGEMENT OF PRODUCTION

Khrustaleva I. N., Kolodyazhny D. Yu., Khrustalev M. B., Gasyuk D. P. The integrated model of complex optimization of production process at machine-building enterprise

Comprehensive optimization of the parameters of the production process, carried out as part of the technological preparation of production, is one of the key tasks for the machine-building enterprise. The efficiency of the optimization process directly depends on the level of detail of the process under study and the optimal choice of targets and control parameters. The paper presents the results of a structural analysis of three types of processes: the process of planning the parameters of loading technological equipment, storage systems and vehicles; cargo transportation process; the process of forming material flows implemented at the enterprise. For each type of process, a description of the hierarchical model is presented, as well as vector optimization criteria are formed. On the basis of hierarchical models of these types of processes, an integrated model of complex multi-criteria optimization of production process parameters was developed in conditions of maintaining the existing structures of technological processes of mechanical processing and the range of products.

Keywords: production preparation, integrated model, process decomposition, pareto optimization