Різання та інструменти в технологічних системах

Постійне посилання на розділhttps://repository.kpi.kharkov.ua/handle/KhPI-Press/62923

У збірнику публікуються наукові статті, у яких висвітлюються актуальні питання в області механічної обробки сучасних матеріалів із застосуванням високопродуктивних технологій, нових методів та вимірювальних приладів для контролю якості оброблених поверхонь і високоефективних різальних інструментів. Висвітлюються аспекти оптимізації й математичного моделювання на різних етапах технологічного процесу.

Рік заснування: 1966. Періодичність: 2 рази на рік. ISSN 2078-7405 (Print)

Новини

Збірник «Різання та інструменти в технологічних системах» включено до Переліку наукових фахових видань України з технічних наук до категорії «Б» згідно Наказу МОН України №409 від 17.03.2020 р.

Переглянути

Зараз показуємо 1 - 20 з 82

Actual contact area on the worn clearance face of the cutter with the round kyborite insert
(Національний технічний університет "Харківський політехнічний інститут", 2023) Manovytsky, Olersandr; Klymenko, Sergii; Klymenko, Serhii; Kopeikina, Maryna
For a tool equipped with a circular cutting insert, a dependence is proposed for calculating the nominal area of the contact area on the back surface. It is proved that the actual area of the contact area of the tool differs significantly from the nominal one due to the presence of a system of micro-irregularities, which makes a difference in the assessment of machining process parameters. Using the example of a tool equipped with a circular cutting insert made of polycrystalline cubic boron nitride ciborite, an approach to determining the actual contact area of the back surface with the workpiece during finishing turning of hardened steel is considered. The possibility of taking into account the influence of the system of irregularities in the contact area, determined by the parameters of its topography, on the size of the actual area is shown, and the ratio of the actual and nominal areas of the contact areas of the tool is determined, and it is found that, depending on the degree of development of the microrelief, the ratio of the actual and nominal areas of the contact surface of the cutter differs by at least 20%. It is shown that the actual contact area is also related to the total length of the main and auxiliary cutting edges, determined by the maximum values of the main and auxiliary angles in the cutter plan, and the size of the wear chamfer on the back surface of the cutter.
Alteration of the cutting force components in tangential turning
(Національний технічний університет "Харківський політехнічний інститут", 2023) Sztankovics, István; Pásztor, István T.
In the development of cutting procedure, the study of the cutting force is important to evaluate the possible loads and elastic deformations in the machining system. The unusual relative position of the cutting tool leads to a changing characteristic of the cutting force in tangential turning. Therefore, it is particularly important to study the values and ratios of the cutting force components in different setups in this finishing procedure. In this paper the depth of cut, feed, and cutting speed are changed, and the effect of these parameters are analysed on the major cutting force, feed force and passive force. The full factorial design of experiment method is applied in the selection of setup parameters and the evaluation of the results. The maximal values and the ratio of the force components were analysed by the determination of equations.
Aluminum matrix composites alternative for brake rotor applications
(Національний технічний університет "Харківський політехнічний інститут", 2024) Khattab, Afraa; Felhő, Csaba
This literature overview examines the capacity of using aluminum matrix composites (AMCs) rather than conventional grey solid iron in brake rotor packages. Driven by the preference for lighter and more environmentally friendly vehicles, AMCs offer several benefits, including decreased weight, advanced thermal properties, superior put-on resistance, and an optimized breaking system. Studies have concluded that AMCs can gain weight reductions of up to 60% compared to cast iron, resulting in stepped-forward gas performance and automobile management. Besides exhibiting superior thermal conductivity and lower thermal enlargement, it results in better heat dissipation and a reduced danger of warping and cracking. The advantage of using ceramic reinforcements, which include SiC, Al2O3, and B4C, is that they can enhance the damage resistance of AMCs, leading to a longer service life for brake rotors. У цьому огляді літератури розглядається можливість використання алюмінієвих матричних композитів (AMК) замість звичайного сірого чавунав пакетах гальмівних дисків. Керуючись перевагою більш легких та екологічних транспортних засобів, AMКпропонують кілька переваг, включаючи зменшену вагу, покращені теплові властивості, чудову стійкість до корозіїта оптимізовану систему руйнування. Дослідження дійшли висновку, що AMК можуть зменшити вагу до 60% порівняно з чавуном, що призводить до поступового підвищення продуктивності газу та управління автомобілем. Крім того, що він демонструє чудову теплопровідність і менше теплове збільшення, він призводить до кращого розсіювання тепла та зменшує небезпеку деформації та розтріскування. Перевага використання керамічних підсилювачів, які включають SiC, Al2O3і B4C, полягає в тому, що вони можуть підвищити стійкість до пошкоджень AMК,що призводить до більш тривалого терміну служби гальмівних дисків.
Analysis and comparison of the waste management development in Hungary and Slovakia
(Національний технічний університет "Харківський політехнічний інститут", 2022) Akkad, M. Z.; Bányai, T.
Waste production is an indispensable human process that happens daily in all communities. With the population increase and the industry developments, the waste amounts are growing, and their treating processes are taking a bigger share of the transportation and handling tasks in the city logistics. These waste collection, transportation, and treatment are described as waste management has been investigated and developed especially with the various application, solutions, and developments in the logistics, transportation, and industrial areas. Also, with the higher attention to the environmental impact in the different areas, the green aspect of waste management takes more importance particularly in city logistics where congestion occurs regularly. Within this work, waste management is analyzed in Europe generally and Hungary specifically. Eurostat database is used for that purpose next to previous research work tackling this topic. Also, a comparison between the waste management operations in Hungary and Slovakia is discussed to show the difference of these operations’ developments between the two countries between 2014 and 2020.
Analysis of selected function-defining 2D surface roughness parameters in tangential turning
(Національний технічний університет "Харківський політехнічний інститут", 2023) Sztankovics, István
Among other, more frequently analysed surface topography parameters, the function-defining parameters must be analysed in different machining procedures to outline their application possibilities. These values are the core roughness, the reduced peak height, the reduced valley depth, the skewness, and the kurtosis of the roughness profiles. Tangential turning is a promising machining procedure, which can produce ground-like surfaces with twist-free properties by defined cutting edged tools. The achievable productivity is also very high. Therefore, in this paper, these roughness parameters were analysed from 2D roughness profiles measured on surfaces machined by tangential turning.
Analysis of the Abbott-Firestone curve ona diamond-burnished surface
(Національний технічний університет "Харківський політехнічний інститут", 2024) Smolnicki, Szilárd; Varga, Gyula
In theresearch we provide a brief overview of the context of the topic, starting from the issues of energy efficiency and environmental awareness and sustainable development, through the positive properties of alternative forms of processing such as diamond burnishing, to the examination of the surface finish, which plays a key role in the relationship between surface quality and diamond burnishing.In the first chapter of this paper, the science of sustainable development, industrial ecology and its different systems models are presented, leading to the three pillars of sustainable development. In the same chapter, we touch on the relationship between energy-and eco-efficiency, their characteristics, recent research results and impacts.Wepresent the dimensions and material quality of the test piece on which the tests were carried out. This will be followed by a description of the technological characteristics of the turning and diamond-burnishing processes. У дослідженні ми надали огляд контексту теми, починаючи з питань енергоефективності, екологічної свідомості та сталого розвитку. Ми розглянули позитивні властивості альтернативних методів обробки, таких як алмазне полірування, і звернули увагу на поверхню підкладки, яка є ключовим фактором у взаємозв'язку між якістю поверхні та алмазним поліруванням. У першій частині статті ми представили науку сталого розвитку, промислову екологію та її різні системні моделі, а потім звернулися до трьох стовпів сталого розвитку. Було обговорено взаємозв'язок між енергетичною та екологічною ефективністю, їхні характеристики та останні результати досліджень. У наступному розділі ми описали розміри та якість матеріалу дослідних зразків, які були випробувані. Потім були представлені технологічні характеристики процесів точіння та алмазного вигладжування.
Analysis of the effect of varying the cutting ratio on force components and surface roughness in face milling
(Національний технічний університет "Харківський політехнічний інститут", 2023) Felhő, Csaba
Traditional machining processes, such as face milling, still play a very important role in the production of machine parts and are the subject of ongoing research. One important area of research is the investigation of high-feed milling processes. However, due to the increased feed per tooth value fz, it is advisable to reduce the depth of cut (aₚ) in order to maintain the cutting forces at an appropriate level. In this way, the ratio of these two technological parameters, the so-called cutting ratio, changes and we can move into the range of inverse machining, where aₚ / fz < 1. In this paper, the consequences of this change is investigated on the surface roughness and the components of the cutting force, and it is discussed how the optimal cutting ratio can be found.
Analysis of the Sbi and Svi functional indices in hard machining
(Національний технічний університет "Харківський політехнічний інститут", 2022) Molnar, Viktor
The functional requirements of precision machined parts can be expressed among others by topography parameters. In the automotive industry there is an increased need for the application of high-accuracy quantifying parameters. In this study wear resistance and the fluid retention ability-related 3D surface texture parameters are analyzed based on hard turning and grinding experiments. The less frequently applied functional parameters (Sbi and Svi) are compared to the high-accuracy volume parameters (Vmp and Vvv) to obtain information about the reliability of the former ones. It was found that the correlation between the two types of parameters are quite weak.
Analytical analysis of the theoretical surface roughness in the case of burnishing of cylindrical workpiece
(Національний технічний університет "Харківський політехнічний інститут", 2023) Ferencsik, Viktoria
In the last decade, ensuring the highest possible surface quality of manufactured parts has been given a major priority, so more and more emphasis is being placed on the examination and development of finishing treatments that can effectively ensure increasingly stringent surface roughness. For this purpose, diamond burnishing - which is a widely used cold plastic technology - can be used productively as it can improve the surface roughness of the material. But even though due to the development of engineering technology, new possibilities and methods are constantly being developed to examine individual material structure changes, the ability to plan the surface roughness is very difficult. This paper focused on the determination of theoretical roughness to establish a mathematical model that can predict and analyse the relationship between experimental process parameters and surface roughness parameters. To validate the model, real experiments were performed, where the surface roughness were measured before and after the application of burnishing process on low alloyed aluminium shaft pieces.
Analyzing surface integrity elements of hard turned 16MnCr5 steel
(Національний технічний університет "Харківський політехнічний інститут", 2023) Molnar, Viktor
Surface integrity plays a determinant role in the functional requirement of precision machined parts. In the automotive industry billions of components are manufactured by using case hardened steels. In this study some surface integrity elements, such as surface roughness or residual stress are analyzed based on systematic machining experimental plan to optimize the applied cutting parameters. Recommendations are made for these parameters based on the measurement data and some widely used functional requirements.
Analyzing the effect of the tool pass number and the direction of sliding burnishing on surface roughness
(Національний технічний університет "Харківський політехнічний інститут", 2022) Nagy, Antal; Varga, Gyula
Nowadays, the concern of environmental protection is becoming more and more important in production as well. They often contribute to this by reducing or eliminating the amount of coolants and lubricants, or by using alternative machining methods. One of them is burnishing, which makes a positive effect on surface integrity, while reduces the environmental load. In this paper we examined the change in surface roughness achieved by burnishing after turning on a corrosion-resistant steel workpiece, where the number of burnishing passes and burnishing direction were changed. The results showed increased smoothness, bearing capacity and dimensional stability by increasing the number of passes from 1 to 2, however, the 3 times repetition did not show any additional favorable improvement on the surfaces. In case of the forward-backward-forward burnishing directions, further chipping occurred, in other cases the effect of the directions was negligible on the amplitude roughness parameters, but considerable on the parameters characterizing the roughness peak. The greatest improvement was achieved with the backward-forward settings.
Arithmetic mean height and maximum height of the roughness profile in honing with different feeds
(Національний технічний університет "Харківський політехнічний інститут", 2023) Sztankovics, István
The achievable surface quality is an important factor even in roughing procedures; however, it is most relevant in finishing. Two commonly measured and analysed characteristics of the machined surface roughness profile are the Arithmetic Mean Height and the Maximum Height of the Roughness Profile. In this paper these parameters were studied in bore honing. Cutting experiments were carried out, where the feed rate and the applied honing tool are varied. After the evaluation of the measured 2D surface profiles, the following conclusions were drawn: the effect of the feed rate is not linear; the lowest values of the analysed roughness parameters were achieved by the application of 50 mm/rev. feed rate and a honing tool with 80 grain size and ceramic binder; the difference between the studied roughness parameters was 6.5-8.0-fold.
Automatic control of temperature and power conditions during rough grinding of slabs
(Національний технічний університет "Харківський політехнічний інститут", 2021) Tihenko, V.; Lebedev, V. V.; Chumachenko, T.
The production of high-quality rolled products (slabs), the formation of its surface phase-structural composition, texture, stress state during rough grinding depends on the temperature in the area of contact between the wheel and the slab. During processing, due to geometric errors of the rolled surface, as well as due to local changes in hardness, periodic fluctuations of the instantaneous depth of cut occur, which can be determined indirectly by controlling one of the technological parameters, for example, the power spent on grinding, with subsequent recalculation it to online temperature values. The grinding temperature is described as a control object in the form of an aperiodic link. Computer simulation has confirmed the efficiency of the system for maintaining the specified temperature of slab grinding under various operating conditions that simulate the situations of real production.
Calculation of shear angle when cutting with a tool of a negative rake angle
(Національний технічний університет "Харківський політехнічний інститут", 2022) Manovytskyi, O.; Klymenko, S.; Burykin, V.
The article considers the results of the study of the cutting process in order to obtain the calculated dependences of the shear angle oF the physical and mechanical properties of hard-worked iron-carbon steels and alloys in thermobaric conditions of the cutting process and the value of the negative rake angle which is a typical tool for processing with polycrystalline superhard materials (PSHM) cutting tools. When cutting, the formation of chips occurs in the plastic flow of metal in the area of cutting or fracture with the formation and subsequent development of cracks and the subsequent separation of elemental or stepped chips. A well-known chip shaping scheme with one plane shift and the value of the contact area of the front surfaces of the cutting elements with the allowable material to be removed are used to describe the contact phenomena in the chip forming zone and calculate the shear angle in this plane. It is established that the inverse relationship between the shear angle and the negative rake angle of the cutting element indicates that the increase in the negative value of the rake angle leads to a decrease in the shear angle. The specific elongation and shortening of the processed material at the cutting temperature are defined by the authors as the characteristics of shear plasticity and selected for use in the calculation of the values of shear angles during blade processing. As a result of this work, the calculated dependences of the shear angle values on the physical and mechanical properties of heavy duty ferro-carbon steels and alloys in thermobaric conditions of the cutting process and the value of the negative rake angle, which is characteristic of machining with tools of PSHM equipped.
Causec of different waves of machined surfaces after up and down end-milling
(Національний технічний університет "Харківський політехнічний інститут", 2022) Dyadya, S.; Kozlova, Olena; Karamushka, D.; Kushnir, E.
In modern industry, among the methods of surface treatment is widely used end-milling. Under certain conditions of its use there are self-oscillations, which significantly affect the quality of the treated surface. Various techniques are used to study this influence, in particular, the comparison of the basic fragments of the oscillogram obtained by cutting with the treated surface. It is established that it is formed by the first and last wave of self-oscillations during up and down milling, respectively. But depending on the direction of feed step and the height of the waviness on it have different meanings. Therefore, it is important to determine the reasons that lead to this result. This paper considers the features of each direction of supply that affect the formation of the treated surface. When superimposing fragments of the oscillogram obtained by up milling, it is seen that the deviation of the first wave of self-oscillations from the position of elastic equilibrium starts from the point of incision of the cutter in the part. Therefore, the pitch of the wave on the treated surface depends on the feed and the number of cuts required to cut the first protrusion on the cutting surface. The paper presents a formula for determining the length of the base of this speech. When using it, the discrepancy between the calculated wave step on the treated surface and the measured one does not exceed 4%. In the case of down milling, the last section with waviness on the cutting surface, which is cut and affects the shape of the treated surface, has a shorter base length than the opposite. This is the first reason why the pitch of the wave in the down milling is smaller than in the up. Also at formation of wave on the processed surface at down milling the feature in the form of shift on a phase of waves of self oscillations on each following cut is observed. This increases the cutting time and the length of the cutting surface. Each subsequent forming depression is shifted towards the treated surface with a decrease in its deviation from the position of elastic equilibrium. However, the phase shift direction is opposite to the feed direction. This is the second reason why the pitch of the wave on the machined surface after the down milling is less than after the up. The calculation of the step of the wave of the treated surface after the down milling according to the results of the study of fragments of oscillograms shows that the error does not exceed 12% compared to the measured one.
Comparison analysis of material handling solutions of production workplaces
(Національний технічний університет "Харківський політехнічний інститут", 2022) Telek, Péter
Production and assembling workplaces can be different in manufacturing and physical environment characterisations, or internal structure, involving the applied material handling solutions, which must be suited to the workplace specifications. The general objective of my research is to develop a model which can help to select the most suitable material handling equipment for production workplaces. The topic presented in this paper deals with the comparison of the different handling solutions. After the overview of the material handling model and the handling equipment selection procedure of production workplaces, a comparison analysis of the applicable handling solutions will be introduced. The last chapter of the paper contains an example for the comparison analysis of a given workplace.
Comparison of cutting tool geometries based on cutting forces and roughness of hard turned surfaces
(Національний технічний університет "Харківський політехнічний інститут", 2024) Molnár, Viktor; Szabo, Gergely
Surface quality and energy consumption are two widely studied topics of hard machining. Due to the increasing need of companies for new, more efficient materials, tools and procedures, their manufacturers or suppliers have to deliver innovative solutions from time to time. In this study the latest development of a hard turning insert manufacturer is used in comprehensive machining experiments to show how the new tool (a wiper insert) behaves compared to its standard counterpart. Based on surface roughness and machining force measurement and analysis, this efficiency is proved by quantitative results: the wiper geometry ensures significantly better surface quality, while the energy consumption of the used machine tool is considerably lower. У токарній обробці загартованих сталей ріжучі інструменти постійно розробляються їх виробниками, і широкий спектр застосування охоплюється різними рішеннями, що стосуються інструментальних матеріалів або геометрії. У цьому дослідженні представлені результати експерименту з механічної обробки. Вимірювали та аналізували шорсткість оброблюваних циліндричних поверхонь та зусилля обробки. Механічна обробка здійснювалася стандартною вставкою, а потім її аналогом після доводки. Мета полягала в тому, щоб визначити,чи забезпечує вставка після доводкименше енергоспоживання за рахунок менших сил різання та сприятливу якість поверхні за рахунок нижчих значень шорсткості поверхні.
Decision support method for the applicability of hard turning
(Національний технічний університет "Харківський політехнічний інститут", 2022) Kundrak, Janos; Deszpoth, Istvan; Molnar, Viktor
In this study the applicability of hard turning is analyzed in the case of disc-shaped parts (gear wheels). The relevance of such parts has been increasing in the automotive industry; therefore, the efficiency of large series or mass production has high priority. The novelty of this paper is the collection of factors that has to be considered in preparation for applicability decisions of hard turning in order to ensure efficient machining. This can be the basis of the IT support, i.e. an automation solution for technologists. The introduced process is elaborated on the basis of theoretical considerations and production shop-floor experience.
Determination of reliable area sizes for 3D roughness measurement
(Національний технічний університет "Харківський політехнічний інститут", 2023) Zaghal, Jawad; Benke, Márton
Surface roughness characterization plays an important role in the qualification of machined surfaces. As a result of the development of high resolution 3D scanning techniques, researchers and technologists have more possibilities to analyze surface topography in a more detailed way. The purpose of this study is determining the minimal measurement area size of surfaces hard machined by single-point and abrasive tools. Some important height parameters were analyzed: Sa, Sq, Sp, Sv, Ssk and Sku. It was found that the minimum area sizes vary for the different roughness parameters, however, in several cases minimization is possible, depending on the purpose of the surface analytics.
The effect of burnishing process on skewness and kurtosis of the scale limited surface
(Національний технічний університет "Харківський політехнічний інститут", 2022) Ferencsik, Viktoria; Varga, Gyula
In this paper roughness examination and analysis on burnished low alloyed aluminium surfaces are reported, highlighting 2 parameters from the vertical deviations of the roughness profile from the mean line. From the input parameters of the burnishing process, the effect of burnishing force, feed rate, speed and number of passes are investigated. Measurements of the surface topography – before and after burnishing – are conducted on an Altisurf 520 3D measuring device. The generated and calculated values of the machined surface roughness are analysed in detail with the drawing of the conclusions as well.