Advances in Design, Simulation and Manufacturing IV

The relevance of computer-integrated technologies for manufacturing parts is significant in the world . The purpose of this work is to analyze the quality of cast block crankcase using a universal technology of complex computer-integrated design of cast parts of internal combustion engines using engineering modeling of thermal and hydrodynamic parameters of casting . The results of computer-engineering modeling of thermal and hydrodynamic processes of block crankcase casting have shown that gas-shrinkage defects can be stress concentrators in the part’s structural elements. Therefore, they can affect the strength characteristics during operation. The developed 3D model of block crankcase casting with a technological gating-feeding system allowed creating a finite-difference model of casting and tooling and performing engineering modeling of casting processes in the ICS NovaFlow. The analysis of physical features of the processes of filling and cooling the castings in the mold was performed for the cast block crankcase of 4DTNA1 automobile diesel, the locations and sizes of gas-shrinkable defects were determined according to the Niyama criterion. The research results allowed us to form boundary and initial conditions for modeling the stress-strain state of the block crankcase in the places of gas-shrink porosity formation. Further development of the above studies will be carried out for castings of new types, configurations, other casting technologies, newly synthesized alloys.

In the paper, dependence has been obtained to calculate the contact pressures when drawing down the axisymmetric workpiece without a blank flange collet. The solution is based on the assumptions of the momentless theory of shells. The adequacy of the mathematical model is confirmed by experimental data for a narrow interval of forging blanks. The experiments have been carried out on a specially designed tooling to measure load cell deformation using a strain gauge. All the equipment used has passed metrological control. To calculate the meridional and tangential stresses on the torus-shaped portion of the matrix, dependencies were obtained that contain a term connecting the thickness of the workpiece with the value of the stresses arising during drawing, which more accurately describes their distribution on the drawing edge of the matrix. The expression for calculating the surface contact pressure during the drawing of a cylindrical part makes it possible to consider the friction stresses at the radius of the matrix rounding and calculate the drawing force. The obtained dependence differs from the conventional ones in its simplicity and clarity and can be used at the preliminary stage of choosing equipment for stamping. It is shown that the friction stresses between the contacting surfaces can be controlled over a wide range while achieving a significant change in the stress state and the distribution of deformations in the volume of the workpiece.

In the conditions of finishing and precision turning, the traditional approach to laboratory assessment of the condition of cutters by periodically recording the parameters of the wear zone along the flank surface and subsequent recognition is, in the authors’ opinion, insufficiently effective. It does not consider significant changes (due to wear) in the geometry of the cutting edges and, in particular, in the forming of their sections, the state of which directly affects the quality of the processed surface. Therefore, there is a need for complex control and complex recognition of cutting part states. The article aims to develop an approach to complex recognition of cutters cutting part in finishing turning. The scientific novelty consists of creating classifiers for complex recognizing the states of cutters for finishing turning, using the most informative features of the shape of all wear zones, and analyzing their effectiveness. The research was carried out under conditions of processing hardened steel 115CrV3 on a lathe model TPC - 125 BH1P. On a special laboratory stand, equipped with a vision system, comprehensive periodical monitoring of the condition of the cutting part of the cutters for finishing was carried out. Practical usefulness consists of developing a method for predicting the residual life of cutters for finishing turning, using a set of features characterizing the shape and size of defects and microdefects of all wear surfaces of the cutting part. Timely replacement of a failed tool with a new one provides a significant economic effect.

The research results of the ability to assess the boundaries of structural components’ geometric complexity, which are visible in a metallographic analysis of the metal samples of Welded Steam Pipe Joints, considering the operating time, are presented. The estimation of the complexity of grain boundaries was made based on a statistical analysis of fractal dimensions obtained by the cellular method for measuring the grain boundary length. The fractal analysis of microsection images is carried out using a developed program. The computer system was tested for several samples cut from sections of steam pipelines with different operating times, operated under conditions of creep and low-cycle fatigue. A comparative analysis of fractal dimensions of structural components’ boundaries in the microsections images of various metal sections with different operating times is carried out. The research and comparative analysis are carried out for the heat-affected zone, base metal, weld, and substrate areas. As a result, the possibility of assessing the complexity of the boundaries of structural components in the steam pipelines metal and their welded joints was confirmed based on the analysis of statistical characteristics of the distribution of their fractal dimension.

The problem of modeling the spindle unit’s design for multi-operational lathes equipped with a set of modular tooling according to the rigidity criterion is considered. Structural and calculation schemes of a two-support structure in the form of a constant cross-section beam on duplexed angular contact ball bearings considering linear and angular stiffness are proposed. The procedure for constructing an analytical static formula of a spindle as an analytical dependence of its general compliance on the cantilever’s dimensions is used, which adequately reflects the conditionally constant (spindle on two supports) and replaceable (modular tooling) parts of the object under consideration. With the help of this formula, it is possible to express procedure probing the machine’s working space according to the compliance indicator. Analytical dependencies for finding a rational ratio of the spindle main design parameters from the standpoint of maximum rigidity are proposed. This approach is most effective for typical double-support spindles equipped with a variety of tooling. The efficiency of the APM Structure3D module in solving problems of assessing the stress-strain state, considering the complex mechanism of deformations in supports, is shown. The stress fields, which predetermine the picture of the researched object’s deformation state, are presented. For a comprehensive study of the spindle unit, the capabilities of APM Structure3D to determine the set of natural frequencies and the corresponding vibration modes are used.

Product Life Cycle Support (PLS) becomes a priority direction in mechanical manufacturing. That realize by providing the rational operational parameters and reliability indicators for manufactured machines and their products. The PLS - concepts are an effective tool for the development of functionally-oriented technological processes. The prediction of the product behavior during exploitation using technological inheritability of its properties is an important problem for modern mechanical manufacturing. The technological damageability is proposed to estimate the technological inheritability of material properties during manufacturing products from castings. Analyzing of material degradation of manufactured products using the LM-hardness method is suggested. LM-hardness method, used for control of the dissipation of the material’s mechanical properties, received by means of special devices in fixed conditions. In general, the degree of the material degradation of manufactured products is described using the Weibull coefficient (m). For the first time, it was proposed technological damageability D for analyzing of degradation of the products material structure for castings in sand molds. The influence of the design parameters of the “Sandvik” tool during end milling on the technological inheritability of material properties using the distribution of Weibull coefficient (m) is analyzed.

To increase the wear resistance of the subsurface layers, AISI 1045 carbon steel and AISI D2 tool steel samples were hardened by a laser heat treatment (LHT) followed by ultrasonic impact treatment (UIT). This paper focuses on studying the effects of the separately applied LHT, UIT, and combined LHT + UIT processes on the wear behavior of the hardened surface of carbon and tool steel. The comparison of the surface roughness and hardness after surface treatments are also addressed. The hardened samples were examined after the short-term (15 min), and long-term (45 min) wear tests under oil-lubricated conditions in the quasi-static and dynamic loading conditions. An optical 3D profilometer evaluated the wear tracks. The results demonstrated that the formed fine-grained martensitic structure coupled with high surface hardness and low surface roughness after combined treatment lead to a significant reduction of the wear loss regardless of the steel type.

The paper proposes a significant improvement in the integrated methodology for automated calculation and selection of interference fits. The study’s main task was to find a rational combination of the values of the variable parameters of the complex mathematical model of the area of existence of the fit. The specified search was carried out in the range of a finite set of permissible parameter values that correspond to the conditions for calculating the fit. As an effective tool for performing a large volume of numerical and analytical calculations, the author’s computer program for the automated design of interference fit was used. The research object was the geometric image of the model of the area of existence of the fit parameters in the form of a three-dimensional body as part of the complex of a multiparametric mathematical model. For solving this problem, one of the projections of the model of the area of existence of fit parameters is described analytically based on the theory of R-functions. In the research process, the influence of the fit diameter’s value (the main geometric characteristic of the fit) on the quality and reliability of the shroud joint during its thermal assembly and during the operation was determined. The research results are recommended for improving the mathematical and software tools for computer-aided design of interference fits when choosing the most rational design solution for the given operating conditions and assembly of the joint.

The development and dissemination of practical additive technologies applications have become a significant trend in technology development in various activity fields. Medical engineering is one of the industries where such technologies already have a tangible effect and will become even greater in the future, especially in the manufacture of customized implants. In many cases, customized implants provide the patient with a quality of life that other solutions cannot offer. Simultaneously, the correct application of medical engineering solutions in this area requires enhanced engineering support. The point here is not about the optimal modes of implant formation but the engineering support system for decisions at every step from the initial condition analysis to surgery. So far, considerable practical experience has been gained, and many publications have appeared describing individual case implementation. Simultaneously, there is a lack of publications that would give an idea of the wide range of possibilities for using additive technologies in creating customized implants and their entire system of engineering support. This paper’s results are based on the authors’ own practical experience, implemented based on the Laboratory of Biomedical Engineering at the Institute of Orthopedics and Traumatology of the National Academy of Medical Sciences of Ukraine.

Some features of a new design of clamping mechanism drive for automatic fixing of cylindrical objects in metalworking machines are considered. One of the proposed design features is a rotating input link, which receives input energy in the form of rotational motion. The presented drive’s operation is considered a part of the clamping mechanism with a collet chuck. Furthermore, the clamping mechanism’s interaction with a drive of the main movement of a lathe is described. The dynamic model is presented as a system with lumped parameters, consisting of rigid bodies connected by inertialess elastic-dissipative links. The stages of the backlash elimination and conversion of the mechanism elements’ kinetic energy into the system’s stressed state’s potential energy are considered separately. The obtained results can contribute to the development of methods for calculating this type’s structures’ parameters. They can be helpful in the determination of more optimal geometric-mass parameters of the elements of these structures.

It is shown that pipe parts with an increased diameter of the edge portion are widely used in the automobile industry as connecting adapters for fuel and exhaust systems. Moreover, one of the requirements for the manufacture and further operation of adapters consists of the same wall thickness of the part in each of its sections. This requirement is almost impossible to meet if the diameter of the end of the tubular billet is increased using a traditional expansion process. To increase the thickness of the part at the end after the expansion, various methods of adding strain to the deformation zone in the form of retaining rings, bandages, and spring elements are used. This increases the cost of technology. The paper presents the results of a numerical experiment to determine the optimal conditions for additional loading of the deformation zone using conical protrusions on the punch generatrix. It is shown that this method of increasing the thickness of the finished part wall is efficient and does not require special costs. The thickness of the finished product at the end of the billet will depend on the location of the conical protrusion on the punch, its length, and the geometric characteristics of the tubular billet. A punch with a protrusion at the end of the conical surface’s generatrix has better results compared to a tool with a straight generatrix.

The article focuses on the results and comparative analysis of diamond spark grinding of titanium-tungsten hard alloy T15K6 using various lubricating media - cooling technological mean with irrigation (3% soda solution of water) and solid lubricants (technical stearin, sebacic acid, mixture (1:1) of stearin with sebacic acid. Specific energy intensity BM estimated the efficiency of the process, detailed work As, productivity Q, relative consumption of diamonds in wheel q, and prime cost Cg. The best combination of the indicated characteristics ensures using a solid lubricant based on a mixture (1:1) of stearin with sebacic acid: the increase in productivity Q is 13.8%, the decrease in the indices q is 33.3%, and Cg is 14.5%. The grinding speed exerts the biggest influence on BM and As. The intensity of these growths during grinding with the introduction of a solid lubricant mixture (1:1) of stearin with sebacic acid into the cutting zone is much less (by 12%) compared to the technological cooling mean with irrigation, which makes it possible to increase the range of grinding speeds, the processing efficiency and makes the diamond spark grinding of hard alloys less wasteful and more environmentally friendly.

In this paper, the examination will be focused only on roller cone bits with three cones. The results show that most problems with deviation from the profile are fixed on the holes. The purpose of this is to increase the accuracy of the holes in the rolling-cutter row of the cone for the tungsten carbide insert cutters. For this purpose, from the batch of tungsten carbide insert cutters a statistically controlled group of tungsten carbide insert cutters was selected. The geometric parameters of the shank for the detection of deviations in the surface profile were studied. The obtained data make it possible to state that the cutting speed within the studied limits does not significantly affect the magnitude of the holes breakdown when fine reaming the holes in the rolling-cutter row of the cone body for the tungsten carbide insert cutters fit. Such results indicate significant reserves in improving the accuracy of molding by monolithic carbide reamers. The effect of technological parameters on the statistical relationship between the magnitude of the hole deployment and the roughness of the processing surfaces was also studied. For the sake of clarity of the advantages of solid carbide reamers and reamers compared with those with soldered hard-alloyed plates, the comparative data for two types of reamers are presented.

The article is devoted to the development of electrohydraulic drives for technological equipment. The engineering method for the design calculation of automatic electrohydraulic rotary motion drive with volume regulation was presented. This method allows evaluating the main parameters and choice drive elements and devices using the maximum load moment and hydraulic motor rotation velocity, predicting its static and dynamic characteristics. The electrohydraulic drive’s automatic control system was proposed considering the control object’s observation noise and stochastic perturbation. The example of design calculation for the automatic electrohydraulic drive parameters for technological equipment for the following input data was performed: maximum load moment Mma x = 120 N.m; maximum rotation frequency nmax = 2100 rpm; reduced inertia moment of the rotating parts J = 0,8 kg.m2. The possibility of using a serially produced axial piston-regulated pump with an inclined disk and an unregulated hydraulic motor with an inclined washer was shown. The drive’s mathematical model parameters as an object of automatic control were determined based on hydraulic machines’ passport data. The research of the system’s dynamic characteristics was carried out.

The paper investigates the process of electrical discharge diamond grinding with changing the polarity of electrodes in time in the cutting zone for processing various materials, and the value of the interelectrode gap is determined. The study aims to determine the optimal value of the interelectrode gap during electrical discharge grinding using the mathematical method of planning experiments. The mathematical method of planning experiments was used, which allows solving the optimization problem under conditions of incomplete knowledge of physical processes’ mechanism. The experiment’s planning gave the result with small errors and made it possible to minimize the number of experiments. As a result of experimental studies, a mathematical model of the limiting interelectrode gap from the electrical modes of electrical discharge diamond grinding was built. The functional dependence of the interelectrode gap was obtained, with the help of which it is possible to determine the value of the optimal interelectrode gap for various electrical parameters of electrical discharge grinding. It was established that the most significant factors that affect the interelectrode gap are the voltage of the ignition pulse and the amplitude of the discharge current.

The oil and gas industry uses drilling, casing, and compressor pipes connected by threaded couplings. Variable tensile forces load a drill string during its operation in a well. Experience shows that pipes are destructed on the body of the pipe or in the thread’s roots. It indicates the importance of studying the contact stresses in the elements of threaded joints. To theoretically determine the distribution of contact stresses in a “pipe - coupling – pipe” thread joint, an integral equation is drawn up with the thread joint’s contact pressure as an unknown variable. To develop this equation, it is necessary to determine the radial displacements and angles of rotation of the normal in the coupling and pipes caused by a single annular force or a single annular moment applied in any normal cross-section. Based on the theory of thin shells of finite length, a method for determining the radial displacements of shell middle surface points (coupling), due to the annular force applied in its arbitrary cross-section, as well as the angles of rotation of the normal to its middle surface caused by these force factors. The fact that the annular moments in the right and left parts of the coupling are opposite has been considered.

Blockchain technology bears an enormous potential to revolutionize markets and economies. Previous research studies on investments in blockchain technology were carried out as part of the paradigm of investing in speculative assets without focusing on the launch of the blockchain at the company level. Currently, there is no scientific basis for properly evaluating the investments in blockchain information management systems that help managers and investors in the decision-making processs. Authors assume that the evaluation/scoring model for investment in blockchain information systems, based on business angels’ investment criteria, is the solution for this market. The study’s research problem is that the vast majority of the stakeholders do not look at blockchain investments through the paradigm of investing in blockchain information management systems from the company perspective. The research aims to identify the main groups of investment criteria for blockchain investments and create a theoretical framework based on the literature overview for further analysis.

Nowadays, many projects and product managers, industry, and portfolio leads understand that data from the project or portfolio can be valuable for increasing their activities. There are many different types of project and portfolio lifecycle processes of managers daily duties: pre-sales and sales, mobilization, delivery, and closure phases. Definitely, in research, we focus on the processes, staffing, governance, and reporting activities. The day-by-day tasks are quite regulated and clearly described using templates and techniques as a company standard. Our literature review shows that Data Science methods can increase the level of project management and project success in several business problems. This study gives new opportunities to improve project management evaluation and results for managers, industry, and delivery leads. The proposed approach allows doing a project, portfolio management, and agile development more accurately, considering best practices and project performance data. Moreover, our results can provide more efficient benefits for different internal and external stakeholders.

Ergonomics is a scientific discipline that today brings together several major scientific disciplines that deal with the rationalization of workspace design. It tries to unite these fields into one comprehensive one: to adapt the environment, especially the working environment, to humans so that it consumes as few biological reserves as possible when using it. This environment should therefore be pleasant for people, not negatively affect their physical and mental strength. In the past, the ergonomics of workplaces were not much addressed. First, a machine, tool, or workplace was created, and only then has an operator sought them. One had to adapt to the machine in order to use its help. The relationship between a person and his workplace began to be resolved only with the emergence of the first ergonomic companies. This work describes the Rula analysis and the relationship between ergonomic analysis and REFA time analysis. The application of individual methods is followed by evaluating results and determining individual problems at workplaces. Based on the identified shortcomings, proposals are made that partially or entirely eliminate these shortcomings. The effectiveness of the designs is retrospectively tested by ergonomic methods and subsequently evaluated.

The ongoing implementation of Industry 4.0 in all segments of society will improve many aspects of human life and initiate many changes in business, production processes, and supply chains from raw materials to finished products. The implementation of new business methods leads to the transformation of production models and production processes, consumption, transport, and supply. Industry 4.0 enables the adaptation of production processes in the industry to full intelligent automation. In other words, it enables the introduction of self-automation, self-configuration, self-diagnosis and solution, knowledge, and intelligent decision-making, owing to the innovations and their implementation in robotics, smart sensors, 3D printers, Internet of Things (IoT), and Big Data technology. The essential quality shift in the implementation of Industry 4.0 in production processes is the implementation of AGV service robots (automatically guided vehicles) in the automation of transport operations in the production process itself (such as transport of raw materials, semi-products, and finished products), on assembly lines, storage of finished products and supply of finished products. The implementation of service robots in the production process is amortized very quickly if they are in operation for 24 h, while the investments can pay off in 2–3 years, and the system operates for about 15 years. The availability of work itself is about 98.5%. The implementation of service robots optimizes production time and costs, thus providing high productivity. The paper presents the annual application of service robots in logistics and the application of AGV service robots with different structures in production processes.

The use of a single computer-aided control to automate production and its preparation creates a common technical base when the adjustable online model of the profile gear grinding operation allows compensating for the lack of online sensors built into the gear grinding system. In this case, the automation of design and production within a single integrated CAD/CAM/CAE system appears to be a single technological process in which not only general but also phased results are defined. This becomes possible by optimizing the entire (and not only partial) sequence of work performed. The introduction of negative feedback from the built-in online sensors of technological information (when such sensors are available) allows, based on monitoring the grinding system state and output parameters, to correct the setting of the CAE-system which is used not only offline but also in the online mode of CNC machine work. When the adjustment of the CAE system is regulated by deviation, this approach to control makes it possible to increase the efficiency of automated grinding systems. The paper provides a fundamental solution to the problem of making adjustments to the control program of a CNC machine based on the results of measuring the state and output parameters of the grinding system. Given as an example, a step-by-step sequence of actions to determine the parameters of grinding of complex-shaped machine parts (for example, gear wheels) makes it possible to understand the algorithm of operation of an intelligent self-training grinding system.

The research aims to choose a strategy for transport companies’ behavior in the context of the development of Industry 4.0. It is proposed to use a mini-maximum model as an optimization function. This model proposes to make a management decision based on the accounting of primary capital investments for trucks purchase and costs associated with rolling stock operations. The article presents an initial algorithm for accelerating decision-making by creating your software product for specific transportation conditions. This approach allows managers to search faster for the optimal transport option of any production, which is necessary for the concept of industry 4.0. The article provides an example of calculating the creation of a rolling stock fleet for goods transportation into the retail chain of supermarkets in Kharkiv. This approach is universal and can be used to choose the best option for delivering goods between enterprises when transporting raw materials, agricultural goods, mail, etc. The approach is universal for making a correct management decision for different types of routes and allows managers to form the necessary fleet of vehicles with minimal investment and the highest productivity.

The following article makes a case study with an SAP ERP system, which integrates with an external Web Service using API access. Algorithm implementation is demonstrated with all transactions used in SAP ERP. However, it should be noted that a limited version of SAP ERP S/4HANA version release 2.00.044. It was pointing to the capabilities test between the external system and the ERP system. During the experiment, the ABAP programming language and the built-in SAP ERP background job are used and configured as needed. The received data is stored in the SAP ERP data warehouse, modified to save the new data. The main result is to provide integration capabilities. Utility to use the Web Service and the ERP system’s integration technique to enable the capability’s regular use. The experiment shows that the SAP ERP system can be integrated from an external source and store data to improve future business processes and increase its business values. The approach allows for the development of future frameworks and the expansion of ERP systems between external systems.

Emerging Industry 4.0 technologies are changing very fast, and in few years, technologies reach a new level of maturity, or new technologies are introduced. This makes it difficult for manufacturing companies to keep track of the fast development and evaluate a future introduction of new technologies related to the Fourth Industrial Revolution. Therefore this work aims to realize an Industry 4.0 technology radar for industrial organizations based on the Gartner Hype Cycle Curve. This tool aims to analyze new emerging technologies that could affect manufacturing firms, enabling selecting the most suitable ones. The technology evaluation considers three parameters: a technology maturity level, enterprise value, and deployment risk of technologies. The application of such a tool highlights which technologies to include in the company’s future technology strategy. The developed technology radar was applied in a real industrial case study to prove its applicability and limitations.

This article investigates the applicability and compatibility of project closeout processes defined in traditional project management frameworks in cases of agile-developed IT projects. Based on a literature review analysis of three project management frameworks, the hypothesis is formed that traditional project closeout processes are critical in agile developed IT projects. The developed hypothesis suggests an unclear indication of how to trigger a project closeout, the inapplicability of scope fulfillment for closeout trigger, and critical transitions between closed projects and ongoing agile software improvement and maintenance. All three parts of the hypothesis are then individually evaluated by an online survey with 85 participants. As a result of this survey, all three hypotheses are falsified. For most project management practitioners in agile projects, closeout processes are not critical, scope fulfillment is still the most relevant closeout trigger, and the transition to a continues-improvement and maintenance process is seen as principally uncritical.

The article’s objective was to develop a method for analyzing the operational reliability of means of transport, emphasizing destructive factors affecting the disruptions in the continuity of supply. The introduction contains a diagram of the occurrence of adverse events in the transport system. The concept of reliability analysis of rolling stock based on two conditions (its fitness and unfitness) was presented. We describe the proposed method in three stages. The first one is related to activities aimed at extending the fitness condition of the rolling stock. As part of this stage, destructive factors were classified, depending on the rolling stock life cycle phase, with degradation parameters identified and characterized. The second stage concerns diagnostic activities. An approach to assessing damage based on the diagnostic indicator, which resulted in the so-called diagnostic matrix’s suggestion, was developed. The last stage of the presented method includes repair activities, based on which the concept of applying risk measures, including the risk measure of rolling stock unavailability, was introduced. The results acquired based on the presented method are designed to provide data enriching the decision-making process in transport activities, aimed at reducing the risk of failure to perform the transport task. The method of analyzing the reliability of means of transport presented in our work forms part of the author’s work on developing a comprehensive analysis of the operational reliability of transport systems.

In this paper, an Industry 4.0 oriented architecture of a manufacturing scheduling decision support system is provided. This proposal is based on an analysis performed about some other decision support systems architectures found in the literature and based on another analysis that was carried out regarding the results obtained through a questionnaire distributed through a wide set of enterprises in the Iberian Peninsula. This analysis did enable us to realize that the main characteristics considered fundamental to be integrated into the prosed manufacturing scheduling decision support system were, in fact, of upmost importance, within the current Industry 4.0 requirements. Moreover, the main characteristics proposed for integrating the manufacturing scheduling decision support system’s architecture presented were also used to establish a comparative analysis between the proposed system’s architecture and the ones analyzed from the literature. Besides, through this analysis, it was possible to realize that none of the architectures analyzed from the literature covered the whole set of important I4.0 oriented characteristics proposed.

The concept of Industry 4.0 is inflected in many areas with the introduction of automation, robotics, or modern storage systems with a key element of digitization. An important area for implementing the elements of Industry 4.0 is internal logistics because the supply of production lines and material storage are among the company's key processes. The complexity and irregularity of processes can be automated and changed into an autonomous form based on the concept. The article deals with internal logistics and describes new approaches to the evaluation of logistics processes based on the developed methodology. The methodology design is based on theoretical foundations, and therefore the main part of the article describes the main areas entering the new methodology. Internal logistics is structured into five main dimensions, which completely cover it. According to the company maturity, dimensions are divided into six levels, where the highest level corresponds to Industry 4.0 principles. The evaluation is based on maximizing the criterion function and point evaluation from structured interviews with company members. After partial results from each dimension, it is possible to evaluate the current company level in internal logistics, which is the primary goal. The methodology is therefore mainly of a diagnostic nature.

The article analyzes mobile technologies that are the most widely used in a modern technical university’s educational process. It is noted that under certain conditions for test control on mobile devices, technologies that are limited to the use of students’ mobile devices will be preferred. It is emphasized that for the successful mobile devices use in the knowledge test control of students. It is necessary to consider the features of practical classes on professional and practical training of future engineers. Such features include the widespread use of graphic materials at all training stages and holding a part of the practical training in specialized classrooms without access to mobile Internet. The mobile application SSUquestionnaire-m is described, which allows one to consider the features of engineering training listed in the article and ensure participation of all students in the classroom in control activities at the same time.

Informatization of Ukrainian higher education institutions is a key priority of the state education policy, one of the directions to improve HEI’s IT infrastructure. The paper aims to develop an integrated quality assurance information system to enhance institutional aspects of higher education institutions’ study programs. Therefore, there is an urgent need for all stakeholders to develop, at the university level, a service-oriented architecture to assure the quality of higher education with mandatory elements, for example, student survey results, student ratings, university teachers’ rating, educational programs, results of uniqueness verification for scientific research and qualifying papers, review of educational programs for higher education applicants etc. It will allow to unify the approaches to electronic resource management and accelerate the integration of multi-level HEI quality assurance resources into a single portal. The paper presents a quality assurance information system, which allows processing students’ feedback to provide HEI’s authorities’ decision making.

The research aims to develop a mobile learning engineering application, presenting the form deviations according to ISO 1101. This application aims to improve the quality of tolerances and dimensional control and 3D Modelling courses for engineering students, covering the following lines of studies: design, robotics, industrial and mechanical engineering. The previous studies focused on mobile learning’s impact on student achievement show that the method could be one of the promising educational technologies. The educational applications used on mobile devices develop a friendly environment and generate a positive effect on learning. The authors conducted a detailed analysis of the educational applications presenting geometrical tolerances available in Google Play. This paper also presents the advantages and disadvantages of the published applications. In 2018 we published the educational android application ISO Checker. They are using this mobile application integrated into the engineering courses students transmitted positive feedback. Students are hi-tech learners, and they are in trend with current technological innovations in education.

The version of solving the relevant problem of increasing the innovative activity of engineering specialties students by organizing the academic environment is proposed. The purpose of the activity is to update future engineers and working citizens’ professional competencies and ensure transparent conditions for evaluating instructional designing results. The ways of implementing the project-oriented training principles in the technical university are presented, which will allow to actively involve students in scientific and innovative activities within the educational process and the performance of qualification work. The authors have proposed a model of the information system based on the use of electronic document flow, implemented, at this stage, for the organization of the activity process. The proposed approaches to engineering education will allow to use of student youth’s potential for the development of innovations by scientific-educational project teams and minimize the costs of ensuring the functioning of single information space of innovation-project activity.

Nowadays, students naturally prefer using information and communication technologies in various situations. That led to their different attitude to information and the way they perceive and process information. On the other hand, engineers’ widespread use of information and communication technologies in their job has changed the goals, learning content, methods, forms, teaching aids, methods, and teachers and students’ interaction. The article’s purpose was to analyze a range of tools in terms of didactic tasks that could be successfully solved. The paper deals with the review of resources enabled revealing some learning areas which the information technologies can support: activation of various external senses through the use of multimedia, automation of calculations, improve graphic part of the design, organization of a creative educational environment, optimization of the time-consuming processes of learning outcomes control. The ideas for the organization of students’ cognitive activities of higher levels and learning software for implementing the ideas are presented in the article. The conclusion about the necessity of the educational process updating under the information technologies application was made. Being oriented on the development of the creative potential of engineering students, the information and communication technologies influence goals, learning content, teaching forms and methods as well as cooperation of teachers and students providing development of students’ information literacy, skills of processing information, creation and joining ideas into new combinations and transferring them to different situations to provide engineering students’ preparedness for the innovative engineering activity.

In machining thin-walled parts, determining the optimum machining strategy and the criterion selection of milling parameters is highly relevant. This study addresses the gap in the variety of computer-aided machining parameters calculation solutions. Thin-walled parts are broadly used in many industries due to their efficiency and lightweight. But there are many barriers to surface formation processes. Therefore, the features of thin-walled parts in modern manufacturing preparation have to be taken into account. Furthermore, to provide machining parameters information in a wide range, an intelligent selection method of parameters is essential for a robust basis in the progressive Industry 4.0 concept. The research is laid down in the context of production digitalization in Industry 4.0 thus represents linkage of data, analytics, and interface interaction. The software solution interface is a calculation application consisting of modules of thin-walled part geometrical and material properties, machine, tool, removal, cut parameters, and the area of computed results. The solution database is based on the resultant values collected from mechanical engineering literature, static and dynamic finite element modeling of thin-walled part response under applied loads.

One of the promising directions for increasing the efficiency of parts processing with diamond tools is studying the mechanics of contact interaction based on the theory of elastic-plastic contact interaction of rough surfaces. The contact interaction theory allows you to establish the optimal requirements for diamond tools, processing modes, and the workpiece’s initial parameters. This study discusses a method for determining the contact pressures directly in the honing process of conical holes. The existing methods are based on theoretical calculations or require significant equipment modernization with subsequent analysis of the obtained data. The proposed method is simple and considers the distribution of the linear contact load of the honing bar along the generatrix of the conical hole in the workpiece. The method is based on the usage of strain gauges which are characterized by small dimensions, low cost, and high measurement accuracy at any stage of the technological operation. The results of static and machine experiments showed the qualitative characteristics of the tool-workpiece contact.

The paper presents computer simulation results of the equivalent stress distribution in the surface layer of the diamond burnishing and ultrasonic burnishing products. Finite element analysis was carried out using Third Wave AdvantEdge (TWA) and Solid Works CAE systems. The simulation considered the physical and mechanical properties of both processed and tool materials. The elastic modulus of the processed material Epm was found to have the most significant influence on equivalent stresses in the surface layer of the processed materials, which predetermines the operational properties of products. The Epm values served as a basis in simulation experiments to study the effect of the technological parameters (burnishing force P, burnishing speed V, burnishing depth t, and the burnisher radius r) on equivalent stresses σeq in the surface layer of the burnished material. The primary influencing technological factors in the analysis of the equivalent stress distribution during diamond ultrasonic burnishing were the vibration frequency of the tool f, the radius of its working surface r, and the elastic modulus of the solder Esol. As a result of the simulation, rational values of the technological parameters of the diamond burnishing and ultrasonic burnishing were determined. The study showed that the optimal choice of the technological parameters should consider both the equivalent stress distribution in the surface layer of the products and the factors influencing the tool wear observed under a particular processing mode.

This paper investigates the dynamic behavior of the milling of complex shaped thin-walled components. As an interrupted cutting characterizes the milling process, a detailed study of the tool entrance point in relation to the vibration of the part is performed. Milling tests were performed on two thin-walled workpieces with different static and dynamic characteristics. The rigidity of the milling tool was much higher than the rigidity of the workpiece. End milling of thin-walled components deals with short cutting lengths, contributing to a decrease in the number of regenerative waves on the cutting surface. As a result, there is less than one regenerative wave beginning from relatively low spindle speed. Therefore, vibrations in high-speed milling of thin-walled structures are rather caused by resonance phenomenon than by self-excited oscillation. These findings have been supported by experimental validation where two thin-walled structures have been machined. The worst processing conditions occur when the tool impacts the workpiece when its amplitude of vibration is high.

A dynamic model of the external turning of the screw workpiece outer edge is worked out. The differential equations of the system motion to determine the torsional and linear vibrations of a screw workpiece, a mandrel, and a cutter are deduced. Based on research analyses, the analytical dependences for determining the dynamic loads on the system are developed. The graphic dependences of variation value of cutting force in time are developed, as well as the angle change of screw workpiece deformation in time, and the linear deformation while turning the screw workpiece outer edge. The cutting conditions for turning the screw workpiece outer edge are experimentally specified. According to the results of the experimental study of turning L-shaped auger spirals, outer edges made of 30 Steel (eq. C 30), 20 Steel (eq. C 22), and Steel 08kp (eq. St14), the increase in cutting speed reduces the cutting force. The increase of cutting depth and feed leads to increased cutting force.

Most S-band waveguides are manufactured from a calibrated rectangular tube supplied with the required channel surface accuracy and quality. However, for the compactness of the transmission line, waveguides are made with corner bends and variable cross-sections, which are made by welding or soldering. During manufacturing, defects and deformations occur in the weld zone, which are eliminated by finishing. The main problem here is the assurance of required characteristics of current-carrying surface in weld zones. Several methods for machining waveguide channels provide the necessary roughness, although not all of them apply to rectangular cross-sections and, for machining, corner bends. Previously, the influence of the micro roughness height on the waveguide electrical characteristics was studied, but different finishing methods create their characteristic micro-relief, the direction of micro roughness, a certain degree of work hardening; all these factors also affect the electrical characteristics of working surfaces and require further research. In this work, comprehensive studies have been carried out to study various methods and tools for finishing, making it possible to machine hard-to-reach places of waveguide corner bends, including ensuring the waveguide electrical parameters. Based on the work results, rotating polymer abrasive tools are recommended to finish the weld-affected zones of waveguide corner bends, which provide a favorable surface micro-relief and improved electrical parameters. A model is proposed that makes it possible to predict the attenuation coefficient taking into account the presence of areas with inhomogeneous roughness.

A method for determining the most dangerous zones of the hob cutter to develop the fastest wear of teeth and edges by the criterion of maximum friction on the contact surfaces has been developed. The geometric model of 3D undeformed chips, which is the basis for determining the force and tribological load, considers the actual shape of the transition surface in each gap, considering the shape and size of the inner surface of the chips, which is formed during the previous axial position of the hob. The cutting force was investigated as a function of the cross-sectional area and the chip compression ratio. This value is set depending on the variable thickness of the cross-sections and is determined using the Deform 2D software. The effect of changing the actual geometry of the cutting wedge of the hob’s teeth on friction and contact conditions on the flank face of the trailing edges ultimately determines the maximum wear of the hob cutter.

Slide burnishing is one of the methods of metal processing that use the phenomenon of surface plastic cold deformation. This article presents the results of a study investigating the effect of slide burnishing on the surface roughness of 42CrMo4 steel shafts. The burnishing process was performed with the use of a polycrystalline diamond tip tool. Before burnishing, the samples were subjected to turning on the toolmaker’s lathe. Investigations were conducted based on PS/DS-P:Ha3 Hartley’s plan, which makes it possible to define the regression equation in the form of a second-degree polynomial. Moreover, the artificial neural network (ANN) models have been used to predict the surface roughness of shafts in the burnishing process. The input process parameters considered include the applied pressure, burnishing rate, and feed rate. In all analyzed burnishing cases, the value of the mean surface roughness was reduced. The differences between the experimental data and Hartley’s model do not exceed 24%. The best representation of Hartley’s model was obtained for the burnishing parameters: feed rate f = 0.32 mm/rev, applied pressure P = 130 N, and burnishing speed v = 180 rpm. ANN models were the best predictors of roller surface roughness of the shafts. With the Pearson’s correlation R2 coefficient = 0.99974, the values of prediction errors did not exceed 0.0016249.

Thermomechanical processes that accompany the processing of products made of structurally inhomogeneous materials are considered. The presence of stress concentrators in the surface layer of processed products in various types of heterogeneities of hereditary origin introduced in obtaining the workpiece and subsequent mechanical processing types are the leading indicators of working surfaces’ bearing capacity. The lack of research on the influence of inhomogeneities formed in the surface layer of products during mechanical processing on their functional properties and, in particular, on the bearing capacity or wear resistance, their optimization determines the relevance of constructing a mathematical model of defect formation in the physical and technical processing of structural elements using optimal criteria of fracture mechanics. A numerical and analytical model is developed to determine the thermomechanical state of structurally inhomogeneous materials containing inhomogeneities such as interfacial cracks and inclusions during mechanical processing. Based on this model, the crack resistance criterion's functional relationships with the technological control parameters are determined to ensure products' processed surfaces' quality characteristics.

The analysis shows that one of the most rational ways to increase the efficiency of the grinding process is the choice of rational processing modes because, in this case, occur a comprehensive solution to the problem: first, the need to use expensive lubricant-cooling agent reduced, and second, the need for special grinding wheels and their frequent trueing was reduced. The structure of comprehensive theoretical and experimental studies of energy-power parameters for the technological processes was considered. A system of equations developed based on the hyperbola method was presented, which describes spatial fields of the velocities of particle displacements around the abrasive grain. The order of mathematical operations is expounded, which allows finding important physical quantities characterizing the chip material's deformed state. The deformed state of the cut layer is analyzed – the flow around abrasive grain during plunge grinding. The velocities and dislocation density fields were constructed for a specific example of processing. In the experimental part of the work, the research of the influence of technological regimes and the abrasive tool's characteristics on the quality of the hard-working materials' grinded surface was carried out.

This paper presents an experimental study of the gear shaping process of the internal gearing with a friction coating. It is known that this process is characterized by the occurrence of significant vibrations, the decrease in the stability of the cutting tool, and the ambiguity of the technological parameters. These factors limit the ability to process bimetallic discs with friction coatings on gear-shaping machines. Therefore, the dependence of the amplitude of oscillations of the ram and the table with the fixture for clamping the package of parts on different machining modes are investigated in the paper. The experiment was performed on a gear-shaping machine model TOS OHO 50 and using an accelerometer 7290A-2. To register the vibration acceleration, the Information Collection System “National instruments mod. NI-9234” was used. Also, during the experiment, the analysis of the period of stability of the cutting tool depending on the number of double runs of the shaper-type cutter and circular feed. The tool’s stability was analyzed by the chamfer wear on the rear surface, which was checked by a microscope. According to the experiment results, the optimal processing mode, according to the tool’s maximum productivity and stability, is proposed in the paper. The application of the proposed processing mode reduces the self-excited vibrations of the technological system, increases the cutting tool’s stability, stabilizes the surface roughness parameters, and increases the gear-shaping process’s efficiency of the package of friction discs.

The grinding process successfully ensures high accuracy of the part, microgeometry, and geometry, then very often grinding reduces such quality indicators as the phase-structure and stress composition of the processed surface. When grinding, high contact temperatures arise, some of which, called critical, have a negative effect on the part’s material and can lead to a change in the phase-structural composition and the stress state. The grinding process must be carried out so that these temperatures do not penetrate to a greater depth than the value of the remaining machining allowance. In this case, negative phase-structural changes occur in the layer of material that is removed. The article describes a technique that calculates the depth of penetration of critical temperatures and adjusts the processing modes so that each subsequent pass does not exceed the metal layer that will be removed.

This work aims to determine the parameters of surface roughness during abrasive processing analytically and to substantiate the technological possibilities of its reduction in the conditions of transition from the micro-cutting process to the process of elastic-plastic deformation of the processed material. On this basis, the minimum possible values of surface roughness parameters during free abrasive treatment are analytically determined. It is shown that the main way to reduce the surface roughness is to reduce the grain size of the abrasive powder and increase the surface concentration of abrasive grains in the cutting zone. Based on the analysis of the graph of the relative supporting length of the micro-profile of the treated surface experimentally established during abrasive polishing, the significant effect of individual deep scratches on the surface roughness is shown. It is established that they occur as a result of the work of larger grains included in the considered grain fraction with a grain size of 1/0 and the different heights of the grains in the cutting zone. Therefore, it is recommended to use abrasive grains with a small range of their size spread during abrasive polishing and use ovalized abrasive grains, which prevent the formation of deep scratches. The obtained results can be effectively used for abrasive polishing of reflective surfaces of space products that operate under light conditions and require high surface roughness.

The profiling of high-precision tool-joint tapered threads is performed according to an algorithm based on a convoluted screw model, which is functionally dependent on the cutter’s geometric parameters and the size of the thread itself. It is proved based on visualization of algorithm that effective production of exact tapered thread from stainless steel is possible only using cutters with a specially calculated profile based on interpolation of a hyperbolic curve. There is created an acceptable geometric model for the cutting part of the thread cutter, the profile of which is a function of the back rake angle. Based on the visualization, it is confirmed that the axial profile of the sides of the tool-joint thread made by the cutter with a non-zero back rake angle is actually curved. On the example of algorithmic calculation of shaping by turning the tool-joint tapered thread size 2 7/8 Reg, it is determined that the use of the cutter model with a back rake angle of 12° and with a usual profile of the cutting edge causes the exceeding of the nominal thread profile side half profile angle by 3–10%, which gives grounds for the use of cutters without correction of their edge profile.

In the process of fine boring of small-diameter holes (d = 10–20 mm), coupled flexural-and-torsional vibrations of boring cantilever bars are excited. It is of practical interest to study such vibrations during fine boring of long (or deeply located) holes with a ratio l/d > 3 (l – the length of a boring cantilever bar). In such cases, a coordinate relationship arises between the flexural and torsional forms. A number of experimental studies have been carried out to assess this relationship and the effect on the emergence of an increasing vibration level. The work studies the features of joint flexural-and-torsional vibrations, the relationship between amplitudes and frequencies, and vibration modes’ effect on the loss of vibration resistance. The experiments were carried out on a test bench assembled based on a finishing-boring machine. Measurements were made by strain and piezometric sensors. Samples of steel and cast iron were bored. The criterion for the cutter resharpening was the relative radial wear and the machined surface roughness.

The paper focused on analyzing the scheme of the effect of heat (cooling) flows on the grinding wheelhead of a cylindrical grinding machine tool with an estimate of the power of heat sources to determine the influence of the temperature factor on the accuracy of machining. The most important sources of heat, which act on the wheelhead body, and were studied in the paper are heat released in the spindle bearings; heat released in guideways; heat released in the cutting zone; heat received by the grinding wheelhead body as a result of the action of heated liquid coolant on its front wall; heat from the airflow, removed by the ventilation system of the grinding wheel drive electric motor; heat (cooling flow) from the airflow arising from the rotation of the pulley and the movement of the drive belts of the grinding wheel drive; heat from the ventilation effect that occurs under the encasing of the grinding wheel as a result of its rotation at high peripheral speed; heat (cooling) supplied to the belt drive pulley of the grinding wheel drive, installed at the output end of the spindle. The mathematical models for determining the quantity of heat for each of the mentioned heat sources are given.

The analysis of the rheological model, which formalizes the influence of the main technological factors on the formation of residual stresses and strains in the cutting process, is described in the article. An explanation of the physical phenomena of deformation processes during cutting and comparing theoretical conclusions with simulation studies results are given. The main task, the solution of which is proposed, is the generalization and system analysis of methodological studies of the influence of the technological factors and the cutting tool’s geometry on the formation of the stress-strain and thermodynamic state of the surfaces of the workpieces during the cutting. Such problem-oriented modeling results are the basis for predicting the impact of technological process parameters on the formation of product’s operational properties. An original scheme for determining the residual strains on top and in the machined surface depth is proposed. The analysis of the influence of technological operation data on residual strain formation was carried out using DEFORM 3D simulation.

Machining AISI 304 austenitic stainless steel is well-known as it is very challenging due to its low thermal conductivity and hardening tendency. High-cutting forces are one of the common problems encountered during the machining of this kind of hard-to-cut materials. An attempt to improve its machinability while ensuring environmentally friendly conditions has been made. This experimental study was conducted from the perspective of performance assessment of machining parameters in turning AISI 304 under dry, minimum quantity lubrication (MQL), and nanofluid MQL conditions with consideration of the cutting forces. Additionally, as a methodology, the response surface methodology (RSM) and quantitative evaluation based on the primary effects plot were used. The study revealed that nanofluid MQL offered encouraging results compared to the MQL and dry conditions. Ultimately, the desirability function optimization method (DF) has been successfully executed to determine the best optimal machining responses under different cutting cooling conditions.

The paper is devoted to studying the process of nitrocementation with cycling heating compared to nitrocementation with isothermal heating. The purpose of thermocycling nitrocementation is to grind the base’s structure and the surface layer of steel type AISI 5140, which produces the centrifugal pump’s shaft. The metallographic analysis showed that the grain score after isothermal and after thermocycling nitrocementation varies from № 5–6 to № 9 in the core and № 5–6 to № 10 in the diffusion layer (respectively). The thickness of the protective layer after thermocycling nitrocementation is 1.50 more than isothermal nitrocementation, which indicates a positive effect of thermal cycling on the saturation rate of the steel matrix. The depth of the protective layer obtained during nitrocementation and surface hardness are the criteria for assessing the shaft’s serviceability. It is established that thermocycling nitrocementation in comparison with isothermal leads to increase cavitation resistance by 0.6–1.5 times. The use of chemical-thermocycling treatment leads to reduced time, grinding of grain, and improved mechanical properties of constructional steel.

Electrophysical parameters of the process synthesis of oxide ceramic coatings in the plasma of spark discharge for electrolytes 1 g/l KOH (S1); 3 g/l KOH + 1 g/l of liquid glass and 5 g/l KOH + 6 g/l liquid glass, and distances between electrodes from 0.05 m to 4.5 m have been investigated in this work. The influence of synthesis regimes on the physic and mechanical properties of coatings has been researched too. Experiments helped us understand that the reduction in coating thickness at a critical distance between electrodes is dependent on the depletion of the electrolyte, and the maximum microhardness is dependent on the growing of the power in separate spark discharges and (or) the growing of the content of Al2O3 in this coating. The influence of the distance between electrodes on its meaning was found with the help of the study on wear resistance. It is experimentally set that the value of the synthesis voltage is influenced by the composition, electrolyte concentration, and the distance between the electrodes: an increase in the distance between the electrodes leads to an increase in the synthesis voltage.

The multi-parameter problem of the optimal design of composite sandwich structures with the honeycomb filler has been solved. For this purpose, the optimization process was divided into several stages according to the reasonable levels of significance of the objective function’s parameters, i.e., minimal weight. At the first stage, preliminary analysis of thermal protection coatings of sandwich structures with the honeycomb filler is carried out, the most rational types thereof are found, the values of physical and mechanical characteristics, as well as the optimal ranges of variation and the initial value of the thickness of thermal protection coatings for different sections of the structure, are determined. At the second stage, the task of choosing the optimal relationship of the thickness of the thermal protection coating, height of the honeycomb filler, size of its cell, and thicknesses of bearing skins is solved, with simultaneous securing of the acceptable temperature ranges for the outer and inner surfaces of sandwich shells and bearing capacity of the rational variant in all critical areas. To further reduce the weight, the honeycomb filler structure is optimized at the third stage by varying the angle of opening of the cell of irregular hexagonal shape and coefficient of its shape in each section of the structure. Implementation of the suggested approach in weight optimization of a real object’s structural parameters showed its efficiency, expressed in a significant reduction of the optimal structure’s weight compared to its initial variant.

The problems caused by synthetic waste have led to the need to develop new materials that can be environmentally safe for living organisms and biocompatible with the environment, replacing widely used synthetic polymers. IF spectroscopy was used to study the chemical composition of the composite and to detect harmful substances. The nature of the relationships of structural components in the compositions was studied using scanning electron microscopy. The impact strength was determined by the Charpy method. The nature of the interaction of system components at the microstructural level is investigated. In particular, the anisotropy of properties, which is ensured by the uniform distribution of cavities in the volume of the composite and good adhesion of microcellulose with casein binder, was investigated. It is established that the composite does not contain harmful, toxic substances and can be positioned as a biocomposite. This material has been shown to have sufficient impact characteristics, in particular, impact strength a = 47 kJ/m2 and can be used in the manufacture of food packaging, such as an alternative to polystyrene.

The work investigates the physical, mechanical, and technological properties of mixtures to manufacture cores in a foundry. The filler is technical salt, the binder is an aqueous solution of sodium silicate, and the hardener is a solution based on propylene carbonate on a silicate basis. These rods are used to make internal surfaces in thin-walled castings. The work proposes a new method of manufacturing cores based on cold-hardening mixtures (CHM), which harden at room temperature. The planned experiment was chosen as the basis for modeling the properties of the mixture. The following parameters were chosen as optimization parameters: compressive strength, friability, and durability. According to the developed mathematical models, the mixture composition was optimized. The optimum binder content is 4.0 to 6.0%, and the hardener content is 0.3 to 0.4%. A technological process of preparing CHM for readily removable salt cores has been developed. As a result, the surface quality of the internal surfaces of castings improved. The cycle of core production was reduced, and the casting cleaning costs were reduced due to the elimination of the decoring process; environmental safety of the technological process was provided to the use of non-toxic materials.

The influence of bias potential on the phase-structural state and hardness of nanolayer multi-period vacuum-arc coatings has been studied using modeling radiation damage during ion bombardment, phase-structural studies, and measurement of microhardness. A significant expansion of the defect formation area was revealed when using layers of multi-element (high-entropy) alloys. For the composition (TiZrAlVNbCr), the depth of defect formation reaches 30% of the total layer thickness (around 14 nm). It was found that for monometallic layers of the TiN/MoN system, the use of a constant potential of −230 V leads to the formation of the phase composition of TiN and γ-Mo2N. The hardness of such a coating is 44 GPa. The use of a high-voltage potential (−1000 V) in a pulsed form allows the formation of TiN and an equilibrium MoN phase, reduces the micro deformation of crystallites, and increases the hardness to 47 GPa. The introduction of layers of high-entropy (TiZrAlVNbCr) alloy nitride into the nanocomposite instead of TiN layers, and thus obtaining a composite (TiZrAlVNbCr)N/MoN, even in a high-voltage pulse mode, leads to stabilization of the nonequilibrium (γ-Mo2N) phase in molybdenum nitride layers. However, the feature of high-entropy alloys associated with low diffusion mobility and high distortion of the crystal lattice makes it possible to achieve the highest hardness of 54 GPa in such a nanocomposite.

The powder technology of structurally inhomogeneous materials of AlCu2 sample formation is developed. The algorithm for image recognition of separate particles’ microstructure of structurally inhomogeneous materials is formed and implemented in the Smart-eye software, which provides tools for analysis of surface and internal properties of structurally inhomogeneous materials. The developed powder technology is applied in obtaining the samples of AlCu2, which are further analysed by the Smart-eye software. The structural characteristics of the starting material (AlCu2), in particular porosity, were predicted. The analysis of the average results of the study of the microstructure of AlCu2 particles is held, which shows that the developed models allow accurate control of the microstructure and properties of structurally inhomogeneous materials obtained based on powder technologies. Improvement of granulometric composition of structurally inhomogeneous materials is proved. Based on the obtained materials developed powder technology, it is possible to predict the structural characteristics of AlCu2 raw materials at a qualitative level. Thus, it is possible to exercise to carry out practical realization of the received results on manufacture.

The general principles for the usage of polymer materials for the manufacturing of orthopedic products are discussed. The current choice of polymeric materials for orthopedic insoles and footwear is based on empirical evidence. In many cases, this choice is made subjectively because there is no information regarding each material’s mechanical properties and their in vitro interaction. The insole functionality will depend on the mechanical properties of the used materials, the target functions of which are: amortization, energy absorption, stiffness, adaptation to the sole of the foot, filling of the cavities inside the shoe, and relieving pressure when walking. Accommodative insoles are suitable for patients with diabetes, early Charcot’s disease, or any form of neuropathy, while functional insoles are best used for treating pronation, plantar fasciitis, and heel spur syndrome. This study aimed to provide objective criteria for selecting materials for orthopedic insoles based on their mechanical characteristics. The mechanical properties of the materials were quantified using standardized methods.

Analysis of the properties of the materials from which the parts of a gas turbine engine are made showed that they must have a high melting point, high strength, high creep resistance, and be machined. Therefore, the best option for strengthening the blades of titanium alloy VT3–1 is the formation in the wear zone of a thermodynamically compatible, heat-resistant, and wear-resistant layer, which is different from the main material of the blade. Samples for research were cut from the bandage shelves of the compressor blade in the shank area: the first - with high-quality soldering relite, the second – the shelf is worn, and there is a defect in the form of a drop. It was found that the main titanium alloy has a homogeneous structure, and the surface of the defective coating has a lower roughness, microcracks. Its local areas differ in elemental composition. Clusters of pores explain the clear and wide grain boundaries of titanium alloy under defective soldering at the boundaries. Such clusters of defects are etched more strongly than the base metal, so the base alloy has a needle-like martensite hardened structure formed by rapid cooling in the air after soldering. It is proved that such defects are formed due to the violation of soldering technology. It is proposed to create a protective layer of composite material VTN-1 with tungsten particles, which contains solid parts of tungsten carbide and titanium-based solder VPr16, to strengthen the working blades in the wearing zone.