Rationalization of modes of HFC hardening of working surfaces of a plug in the conditions of hybrid processing

IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING
Vadim Skeeba, Nikita Vakhrushev, Kristina Titova, Aleksey Chernikov
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引用次数: 0

Abstract

Introduction. The development of a cluster of hybrid metalworking systems in the machine tool industry is associated with a number of positive consequences. First, such systems help reduce production costs by optimizing the use of resources and energy. This is especially true in the face of increased competition and a trend towards savings. Secondly, hybrid systems enable the production of quality products with increased efficiency. By integrating various functions in one process equipment, metalworking processes become more efficient and precise. This reduces the amount of defective products and improves the quality of the final ones. In addition, hybrid metalworking systems have autonomous functionality, which is especially important in flexible engineering production, where rapid changeover and adaptation to various production tasks is required. Thus, hybrid metalworking systems represent an important step in the development of modern mechanical engineering, helping to reduce costs, increase efficiency and ensure high product quality. The purpose of this work is to increase efficiency and reduce energy consumption during surface-thermal hardening of machine parts through the use of concentrated energy sources under integral processing conditions. Theory and Methods. To achieve this purpose, studies were carried out on the possible structural composition and layout of hybrid equipment integrating mechanical and surface-thermal processes. When developing the theory and methods, the main provisions of the structural synthesis and components of metalworking systems were taken into account. Theoretical research is based on the application of system analysis, geometric theory of surface formation and design of metalworking machines. The experiments were carried out on a modernized multi-purpose machining center MS 032.06, equipped with an additional energy source, which was a microwave thyristor-type generator SHF-10 with an operating frequency of 440 kHz, which implements high-energy heating by high-frequency currents. Structural studies were carried out using optical and scanning microscopy. The stress-strain state of the surface layer of the part was evaluated by mechanical and X-ray methods for determining residual stresses. The microhardness of the hardened surface layer of the parts was evaluated on a Wolpert Group 402MVD instrument. Results and discussion. An original method for conducting structural-kinematic analysis for pre-project studies of hybrid metalworking equipment is presented. Methodological recommendations were developed for the modernization of metal-cutting machine tools, allowing high-energy heating with high-frequency currents (HEH HFC) on a standard machine tool system and creating high-tech technological equipment with enhanced functionality. It has been experimentally confirmed that the introduction of the proposed hybrid machine into production in combination with recommendations for the appointment of high-frequency electric power units for integral processing of punch-type parts allows increasing the productivity of surface hardening by 36–40 times and reducing energy costs by 6 times.
杂化加工条件下插头工作面HFC硬化方式的合理化
介绍。在机床工业中,混合金属加工系统集群的发展带来了许多积极的后果。首先,这种系统通过优化资源和能源的使用,有助于降低生产成本。面对日益激烈的竞争和储蓄趋势,这一点尤其正确。其次,混合系统能够以更高的效率生产高质量的产品。通过在一个工艺设备中集成各种功能,金属加工过程变得更加高效和精确。这减少了次品的数量,提高了最终产品的质量。此外,混合金属加工系统具有自主功能,这在需要快速转换和适应各种生产任务的柔性工程生产中尤为重要。因此,混合金属加工系统代表了现代机械工程发展的重要一步,有助于降低成本,提高效率并确保高产品质量。本工作的目的是通过在整体加工条件下使用集中的能量源,提高机械零件表面热硬化的效率,降低能耗。理论与方法。为了实现这一目的,对机械和表面热过程相结合的混合设备可能的结构组成和布局进行了研究。在发展理论和方法时,考虑到金属加工系统的结构综合和组成的主要规定。理论研究是基于系统分析、表面形成的几何理论和金属加工机械设计的应用。实验在现代化多用途加工中心MS 032.06上进行,该加工中心附加能量源为工作频率为440 kHz的微波晶闸管型发生器SHF-10,利用高频电流实现高能加热。使用光学显微镜和扫描显微镜进行结构研究。采用机械法和x射线法测定残余应力,评价了零件表层的应力-应变状态。采用Wolpert Group 402MVD仪对零件表面硬化层的显微硬度进行了测定。结果和讨论。提出了一种用于混合金属加工设备工程前期研究的结构-运动学分析方法。为金属切削机床的现代化制定了方法建议,允许在标准机床系统上使用高频电流(HEH HFC)进行高能加热,并创建具有增强功能的高科技技术设备。实验证实,将所提出的混合机床引入生产,并结合建议指定高频电力单元进行冲孔类零件的整体加工,可以将表面硬化生产率提高36-40倍,并将能源成本降低6倍。
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来源期刊
Obrabotka Metallov-Metal Working and Material Science
Obrabotka Metallov-Metal Working and Material Science METALLURGY & METALLURGICAL ENGINEERING-
CiteScore
1.10
自引率
50.00%
发文量
26
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