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2019 | Buch

Proceedings of the 4th International Conference on Industrial Engineering

ICIE 2018

herausgegeben von: Prof. Andrey A. Radionov, Prof. Oleg A. Kravchenko, Prof. Victor I. Guzeev, Prof. Yurij V. Rozhdestvenskiy

Verlag: Springer International Publishing

Buchreihe : Lecture Notes in Mechanical Engineering

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SUCHEN

Über dieses Buch

This book highlights recent findings in industrial, manufacturing and mechanical engineering, and provides an overview of the state of the art in these fields, mainly in Russia and Eastern Europe. A broad range of topics and issues in modern engineering are discussed, including the dynamics of machines and working processes, friction, wear and lubrication in machines, surface transport and technological machines, manufacturing engineering of industrial facilities, materials engineering, metallurgy, control systems and their industrial applications, industrial mechatronics, automation and robotics. The book gathers selected papers presented at the 4th International Conference on Industrial Engineering (ICIE), held in Moscow, Russia in May 2018. The authors are experts in various fields of engineering, and all papers have been carefully reviewed. Given its scope, the book will be of interest to a wide readership, including mechanical and production engineers, lecturers in engineering disciplines, and engineering graduates.

Inhaltsverzeichnis

Frontmatter

Dynamics of Machines and Working Processes

Frontmatter
Diesel Engine Preheating and Starting Simulation with Modelica Language

The article presents the results of mathematical model and software development for the simulation of diesel engine preheating and starting with the Modelica language. The model is based on the energy and mass balance method, Godunov scheme, Wiebe, and Razleytsev equations, and is a library of Modelica classes which describe the processes in engine systems and mechanisms including air and electrical starters, preheaters, and start facilities tools. The mathematical model includes the description of different boundary conditions, acausal connections, and basic and complex elements, such as a(n) electric and fuel coolant preheater, air heater in gas pipes, and compressed air starting system. The created mathematical model and software provides high speed calculation, reliability and accuracy of results, that is confirmed by comparison with experimental data. The possibility of conjugate calculation of stationary and transient multi-domain processes in various engine systems and mechanisms is ensured.

A. Malozemov, V. Bondar, G. Malozemov
Processes Dynamic Characteristics in the Intake System of Piston Internal Combustion Engine

The experimental studies of gas dynamic and heat exchange characteristics of processes in the intake system were carried out on the full-scale model of a piston engine. The experimental setup and the instrumentation and measurement base for this study are briefly described. The experimental data on the dynamics of changes in airflow velocity and instantaneous local heat transfer in the intake system of a piston engine are presented in the article. The amplitude–frequency analysis of the considered flow parameters is carried out. It is shown that the intensity of local heat transfer in the intake system in a pulsating flow is much lower than for a stationary flow, and this difference reaches 2.5 times.

L. V. Plotnikov, Yu. M. Brodov
Calculated and Experimental Study of Free Vibrations of a Cylindrical Shell

At designing of thin-walled structures for aerospace engineering, it is vital to identify their frequencies and modes of free vibrations based on the results of frequency tests and the finite-element analysis. The paper defines calculated frequencies and modes of free vibrations of a cylindrical shell based on the finite-element model. Experimental frequencies and modes of free vibrations are obtained by the impulse excitation method. The authors used the Modal Assurance Criterion to evaluate matching of the calculated and experimental eigenmodes. However, such evaluation is complicated due to the limited number of sensors (to measure the mode and the frequency of free vibrations) and the presence of initial imperfections not taken into account in the calculated shell model. Based on the study of the Modal Assurance Criterion sensitivity to the difference of the relevant pairs of calculated and experimental vibrations of nodes, the authors have shown the influence of the initial imperfections on the eigenmodes. Based on the results of this study, the authors have identified nodes and areas of the shell with the maximum difference of the compared modes. By adjustment of the calculated vibration mode with regard to the experimental one in the circumferential direction, the authors have improved the values of the Modal Assurance Criterion. The location of the imperfection area and evaluation of its influence are used to specify the eigenmodes of the calculated shell model and to increase the modeling accuracy of the structure’s dynamic characteristics.

D. A. Permyakov, A. S. Pantileev, S. V. Makhnovich
Optimization of Parameters for Fuel Combustion Process of Diesel Working Cycle Improvement

Energy and environmental indicators are two basic criteria to assess technological specification of the internal combustion engine and the perfection of the working cycle in particular. These criteria are controversial; however, they are considerably determined by the quality of the combustion process. In this connection, it is reasonable to improve the working cycle by optimizing the output parameters of the fuel combustion process. The article considers methods for the optimization of the combustion process in diesel engines. The estimation of the specific and the formation of complex criteria, objective function; admissible domain and neighborhoods of the change in the output parameters of the combustion process are given. The numerical values of conventional boundaries separating regions with low, average, and high degrees of control of the combustion process are determined.

E. A. Lazarev, V. E. Lazarev, M. A. Matsulevich
Mathematical Models of Low-Temperature Gas Generator

The low-temperature gas generator (LTGG) is designed to produce gas with a temperature of 350–450 K. The LTTG consists of the combustion chamber with solid propellent and a cooling chamber with granules of a solid refrigerant. Combustion products have a high temperature, which does not make it possible to use them in a whole number of technical devices. Gas cools down while interacting with solid refrigerant granules, which takes part of the gas internal energy to decompose. In order to describe heat and mass transfer processes in an LTGG, we developed a mathematical thermodynamic and one-dimensional models based on one-dimensional equations of continuity, momentum, energy, and the integrity of gas-mixture components. The gas mixture consists of combustion products, refrigerant decomposition products, and air. The mathematical model takes into account the gas-mixture flow in an LTGG, heat exchange with the structural elements of an LTGG, and kinetics of the refrigerant granule decomposition. To activate the mathematical model, a numerical method has been developed for solving boundary-level problems based on the method of finite differences. The system of equations is approximated by means of implicit differences schemes. Solving nonlinear differential equations involves the Newton’s method. The boundary-value problem was solved through an orthogonal factorization.

V. V. Kirillov, R. D. Shelkhovskoi
Iterative Process of AFEM and Ideal Failure Models of Structures

This paper considers the input of ideal failure models of structures for solution of algebraic set of equations by means of iterative process when Additional Finite Element Method (AFEM) is used. AFEM is a variant of the Finite Element Method (FEM) for nonlinear analysis of structures according to the forms of collapse. From the FEM point of view, this problem is the analysis of the structure with some nonlinear properties. The author of this paper suggested and worked out AFEM, which realizes such analysis due to rational iterative process for solving of the set of equations. After fulfillment of this main operation, the problem may be considered to be determined. The end and the direction of iterative process are defined under the condition of an ideal failure model, which is the design diagram of the structure at the moment preceding the collapse. Additional design diagrams and additional finite elements (AFEs) are used for introduction of some units of methods of Limit States (Ultimate Equilibrium) and Additional Loads (Elastic Decisions). This is necessary for creation of an iterative process according to the introduced criterion of collapse. The example of such iterative process is given in the paper.

A. Ermakova
Analysis of Resonator Installation Effect in Intake System of the Diesel Engine on Parameters of Gas Exchange Quality

The results of numerical simulation of the resonator installation effect in the intake system of a diesel engine of dimension 21/21 on wave phenomena, technical, and economic indices are presented. The objective of the study is a diesel engine with eight cylinders: the cylinder diameter is 210 mm, the piston stroke is 210 mm. Diesel (factory designation is 8DM-21/21) is produced at the “Ural diesel-motor plant” (Russia, Ekaterinburg). Numerical simulation was performed in the ACTUS software (Switzerland, Baden). The simulation was performed taking into account the geometric parameters of the elements of the inlet system and the gas-dynamic flow nonstationarity. The article briefly describes the functions and designs of resonators used in the field of engine building. It is shown that the resonator installation in the intake system of the 8DM-21/21 diesel engine significantly changes the gas dynamics of the flow. For example, there is a smoothing of wave phenomena. This leads to an improvement in the quality of gas exchange (an increase in the filling ratio up to 0.5%). At the same time, the specific fuel consumption is reduced by an average of 0.3% while maintaining the power of a diesel engine.

L. V. Plotnikov, S. Bernasconi, B. P. Zhilkin
Calculated-Experimental Estimation of Residual Pipeline Resource for Long-Term Operation

Production and transportation of oil and petroleum products are currently carried out through welded main pipelines, the operational life of which is largely determined by the processes of deformation aging, re-variable loading cycles, the structure and properties of tubular steels, and their welded joints, as well as the type, size, and nature existing defects. Typically, the destruction of such pipelines is due to internal corrosion of the pipes. With the existing estimation of durability and residual life of pipelines, the principle of summation of damages is used, according to which during the operation of pipelines, damage is accumulated in places with a high concentration of stresses. There is a mathematical expectation, the destruction will occur as soon as the total damage is 100%. In this paper, it is shown that the criterion for estimating the longevity of a pipeline (or residual resource) over the entire period of operation depends mainly on two main factors: the ultimate residual plasticity of the metal of the pipe that was in service and the evaluation of the metal damage in the most problematic zone of the pipe. In this case, the decisive influence on the durability with the remaining unchanged parameters of the pipeline is the appearance of the defect, and its geometric characteristics determined during the diagnostic process. The article provides an example of calculating the durability of a pipeline for pumping gas condensate in the area of the Medvezhye deposit (the Kola Peninsula of the reliability site).

M. V. Shakhmatov, E. A. Usmanova, L. I. Khmarova
Dynamic Problem of Direct Piezoelectric Effect for the Circular Multilayer Plate

The authors consider the dynamic axisymmetric problem for the circular bimorph structure consisting of the metal substrate and the axially polarized piezoceramic plate. Its flexural vibrations are due to mechanical stresses (normal stresses) on the end surface, being an arbitrary function of the radial coordinate and time. The rigid and articulated fixing of the plate cylindrical surface is considered. To solve the problem of the theory of electro elasticity in the three-dimensional formulation, the Hankel finite integral transformations along the axial coordinate and a generalized integral transformation (GIT) in the radial variable are used. The constructed closed solution allows a qualitative and quantitative analyzes of electro-mechanic stress field relatedness in multilayer electro-elastic structures. This makes it possible to describe the work and select all geometric and physical characteristics of typical elements of piezoceramic transducers of resonant and nonresonant classes.

D. A. Shlyakhina, O. V. Ratmanova
Dynamic Diagnostics of Limiting State of Milling Process Based on Poincaré Stroboscopic Mapping

The article is devoted to the problem of diagnosing the limiting state of the milling process based on the Poincaré stroboscopic mapping. A method based on a contactless measurement of the distance between the cutter body and the measuring transducer is proposed. In this case, a sequence constructed on the basis of the Poincaré stroboscopic mapping is used, for which statistical estimates to determine the roughness, ripple, and mathematical expectation of the size over the entire treated surface are given. The results of the experiment made it possible to obtain effective algorithms for processing information, which, in the course of cutting, allow us to evaluate the limiting states of the process for obtaining information on the replacement of the tool and its readjustment. The dependencies obtained in the work as a whole coincides with the realistic approach to the estimation of the dynamics of milling processes occurring in metal-cutting machines. According to this approach, it is possible to provide unchanged values of the microroughness height due to the redistribution of the geometric component of the roughness determined by the feed, and the evolutionary component that depends on the trajectory of work and the power of irreversible transformations in the cutting zone.

A. A. Gubanova
Calculation-Analytical Estimation of the Working Cycle Parameters of the Crankless and Crank Engines Under Similar Loading Conditions

The article contains a comparative estimate of the indicators characterizing the working cycle and indicated parameters of each of the engines (in particular, by the indicated value of the tangential and circumferential forces, torque, and indicated power) as applied to similar conditions of use (identifying the cycle conditions, fuel type, identifying the indicated work of the cycle, value of the compression ratio, air excess ration, etc.) in two-stroke internal combustion engines based on the crank mechanism and two-stroke axial engines with identical structural parameters (in particular, cylinder diameter, piston stroke). It is concluded that, for similar conditions of use, the indicator torques formed during the work cycle of these machines are not equal in magnitude. The indicator torque of the CLM engine with a two-period running track of the motion conversion mechanism exceeds the corresponding torque of the internal combustion engine with a crank mechanism by a factor of two. This conclusion also extends to the indicator powers of the thermal machines under consideration.

B. A. Sharoglazov, K. D. Podsedov, M. K. Kuanyshev
Experimental Estimation of Influence of Fuel Injector Nozzle Design on Output Parameters of Tractor Diesel

It has been experimentally established that the modification of the spray nozzle structure of the diesel fuel injector due to the reduction of the length from 18 mm to 10 mm and the diameter from 6 mm to 4 mm of the precision guide, the increase in the diameter of the needle rod to increase its rigidity, the development of the cooling cavity under the differential needle pad increasing the number of fuel supply channels from 3 to 5, increasing the fuel injection pressure from 21–22 MPa to 27–28 MPa and reducing the needle stroke from 0.45 mm to 0.35 mm affects the power and economic parameters of tractor dies spruce. The use of experimental sprayers in a tractor diesel with gas turbine supercharging makes it possible to reduce the specific fuel consumption by 2–6 g/kW h and the temperature of the exhaust gases by 30–50 °C depending on the loading regime, as well as some increases (up to 2%) the coefficient of adaptability for torque. Using sprayers of experimental design in diesel with gas turbine supercharging allows to reduce the specific effective fuel consumption by 2–6 g/kW h and exhaust gas temperature by 30–50 °C depending on the loading mode, also some increase (up to 2%) of the coefficient of adaptability for the torque is registered.

G. V. Lomakin, V. E. Lazarev, V. M. Myslyaev
Dislocation Model of Wheel–Rail Interaction with Locomotive Lateral Fluctuations

The model of interaction between the wheel of a locomotive and a rail based on taking into account the discrete structure of solid deformable bodies using the fundamental concept of metal lattice dislocations was developed. Under the action of applied normal and tangential forces, these dislocations can move and exit to the surface of the crystal or part, if, for example, the Mises yield criterion is fulfilled, which can be considered as a condition for the emergence of dislocations on the surface. The creep force is treated as the total force of destruction of the grippers between the groups of atoms of the wheel and the rail, and simultaneously, the occurring process of sliding the wheel along the rail—as a process of “collapse” of dislocations emerging on the contact surface, i.e., as a translational plastic flow (shear without deformation). It was shown that the creep force depends on the normal and tangential pressures of the wheel on the rail, as well as on a number of additional factors, such as an increase in the number of dislocations with an increase in the deformation rate of the contact zone and the coefficient of destruction of the oxide film. The satisfactory convergence of the results of calculations of lateral fluctuations of the locomotive obtained with the use of the proposed model and known experimental data is shown.

A. N. Savoskin, A. P. Vasilev
Study of Oscillating Process of Harp Screens

The paper presents the results of investigations on the mechanical characteristics of harp screens’ material influence on the screen separation technological parameters. The paper provided a mathematical model of a harp screens’ oscillating process depending on the length of their free area, on the process duty intensity, and on the screened material characteristics. This study found that the amplitude of the relative motion of the rubber strips under load relaxes with the increase of their free areas, and for steel cables, it increases, reaching a maximum at certain values of the technological load. It also had been established that the presence of the load drastically lowers the amplitude of relative motion of the rubber strips, especially in the zone of nondimensional frequencies of the order (0.6–1.4)g, while the amplitude of oscillation of the cable strings in this frequency range varies insignificantly. The use of the rubber-rope strips as working elements of the screening surface makes it possible to increase the “useful screen area” by enlarging the distance between the supports while maintaining high and stable amplitude of the vibration of the strips. The optimization of the mechanical characteristics of the working elements’ material of the harp screens and the conditions of their fixation, provide the intensification of the separation of the sized feed into fractions by eliminating the sticking of the deck plate by clay inclusions and the clogging by “difficult grains”, at the same time it substantially improves the technical and economic parameters of the screening process.

A. D. Bardovsky, A. A. Gerasimova, I. I. Basyrov
To Issue of Application of Method of Dynamic Mechanical Analysis (DMA) to Determine Viscoelastic Properties and Heat Generation in Rubber Elements of Solid Tires

Solid tires are widely used for the undercarriage of track vehicles. Intense dynamic loading of solid tires in the process of operation leads to substantial self-heating and subsequent thermo-mechanical destruction. Reduction in the level of heat generation in rubber is connected with viscoelastic properties of materials. Most often, this task is solved by testing structurally similar samples or full-scale structures using unique stands and equipment. In this paper, we suggest a technique that allows to determine characteristics of rubber using the method of dynamic mechanical analysis (DMA). Rubber samples were tested in the temperature range from 25 to 60 °C and loading frequencies from 5 to 50 Hz. As a result of the carried experiments, we have obtained the dependences of the valid and imaginary moduli of elasticity of the material on the loading frequency and ambient temperature. On the basis of the obtained data, we have constructed the hysteresis loops, calculated the values of specific energy loss per loading cycle, and the power of the heat sources in rubber. The results have been compared with the data in the literature and they showed a good agreement, which enables to apply this methodology to estimate the intensity of heat generation in rubber elements of solid tires.

E. E. Richter, A. V. Ignatova, A. V. Ponkin
Modeling of Dynamic and Economical Characteristics of Life-Saving Device with Flywheel Energy Storage

This article will initially consider the life-saving appliance dynamic model accompanied with computation and analysis of its variables. This life-saving appliance can be used in case of fire on the drilling platforms. The flywheel energy storage converts energy of descent to the rotational energy of the flywheel. After the launch, stored energy can be used to rotate the propeller of survival capsule to increase the distance from the fire. This kind of construction allows decreasing the number of maintenance operations. Moreover, there can be lack of energy in emergency cases. It points out one more profit of this appliance. This life-saving appliance is also analyzed from the economical point of view, and the authors have suggested an economical efficiency Criterion as a marker. The results of variables computation and modeling should be taking into account while developing the construction. The modeling analysis shows the great potential of this life-saving appliance as reliable and safe.

N. N. Barbashov, I. V. Leonov, K. D. Sologub
Experimental Studies on Influence of Natural Frequencies of Oscillations of Mechanical System on Angular Velocity of Pendulum on Rotating Shaft

The article describes the results of an experimental study of the natural frequencies of oscillations of a mechanical system influence on the angular velocity of a pendulum mounted with the possibility of free rotation on a rotating shaft of an electric motor. It is established that at a constant moment of friction in the pendulum support, providing for a change in its mass moment of inertia, a mode of motion takes place in which the motor shaft rotates at a working angular velocity, and the angular velocity of the pendulum coincides with one of the natural frequencies of the oscillations of the mechanical system. The studies have also shown that there are ranges of the values of moments of inertia of the pendulum mass. For these moments of inertia, one can observe the establishment of a stable or unstable angular velocity of the pendulum, which is equal to one of the natural frequencies of the oscillations of the mechanical system.

A. I. Artyunin, S. V. Eliseev, O. Y. Sumenkov
Analysis of Possibilities to Reduce Energy Consumption of Elevator Systems

Much of the time lifting-transport machines operate in transient modes, mostly acceleration and deceleration. There is no doubt that the reasons for the reduction of the efficiency of the machines are instabilities in speed and workloads on these modes, deviations from the optimum values of engine power, and speed and increase of energy losses. Another reason for the increase of energy losses when operating lifting-transport machines is the process of forced braking in case of a necessary stop. Currently, a new class of lifting-transport machines has appeared which can produce regenerative braking. Significant advantages among them have been balanced by the machine having high reliability and service life. However, the methods of calculating the optimum transfer functions in managing the recovery of braking energy up to the end is not yet developed. Below, we consider a mathematical models balanced with the counterweights of elevator systems, the analysis of which reveals the possibility to reduce their energy consumption.

L. Abdullina, N. Barbashov, I. Leonov
Results of Investigating Vibration Load at Human Operator’s Seat in Utility Machine

The results of theoretical research into mathematical model of tractor-mounted utility machine are presented. Regression models were obtained which represents the dependence between the dynamics of vibration acceleration values at the operator’s seat and properties of viscoelastic elements of a cab suspension system at some speed values, and in different operation modes when driving on a surface with hard asphalt concrete pavement. In terms of vibration protection, acceptable parameters of viscoelastic elements in the cab suspension system were determined, and structural and performance characteristics were taken into account. An algorithm for carrying out a computational experiment is described. The indicators of regression models that confirm the quality and reliability of the studies are presented.

I. A. Teterina, P. A. Korchagin, A. B. Letopolsky
Deformation of Thin Elastic Rod Under Large Deflections

The flexible elastic rods undergoing large deflections are widely used in the engineering practice. Analytic solutions for flexible rods are known for some special cases but there are cases when the exact solution does not exist. In such cases, it is expedient to use numerical methods, and the most known is a finite element method (FEM). This paper presents a new numerical method based on second-degree splines of the defect 1 allowing to solve the linearized nonlinear equations with high accuracy for large deflections of a thin elastic rod. The method efficiency is evaluated on the test problem of a pure bending (not shear) of a thin elastic rod. This paper shows that the method ensures the accuracy with a relative error does not exceed 1 × 10−6 for a sufficiently dense number of nodes.

V. S. Zhernakov, V. P. Pavlov, V. M. Kudoyarova
Selection of Incidence Angle at Designing Blade Row of Compressors and Turbines

Selecting angles of attack methods in the design of blade rows (BR) in the composition of compressors and turbines are considered. A number of additions are proposed for using the generalized characteristics of blade profile gratings and A. Howell’s empirical dependencies. To verify the method, the results of factory tests, 2D and 3D CAD/ CAE-simulation of the flow, and gas-dynamic characteristics of the flow parts’ components including blowing of the blade profile gratings were used. It is shown that this method can be effectively used to optimize the geometry of the blade profile gratings in the composition of compressors and turbines and the choice of their operation modes. This allows to significantly accelerate the design and development of gas turbine engines (GTE), gas turbine drives (GTD), and power plants (PP). The proposed method can be used in the creation and use of gas turbines in power, transport, and other areas.

K. E. Rozhkov, I. A. Krivosheev, N. B. Simonov
Synthesis of Controlling the Movement of Digging Mechanisms of Excavators on the Basis of Inverse Dynamic Problems

Using the example of a walking excavator ESh 20.90, the results of studies on the synthesis of an algorithm for controlling the movement of a digging mechanism are presented on the basis of solving inverse dynamic problems to a given type of desired motion. In contrast to the well-known works devoted to the synthesis of control systems for electric drives of digging mechanisms of excavators using rigid and flexible feedbacks on the load in the elastic element, the proposed algorithms are based on determining the required control actions by specifying the exponential law of the change in elastic deformation. It is shown that the control actions found in this way will not depend on the structure of the controller, as a result of which it becomes possible to solve the problem of structural synthesis of the motion control system of the excavator digging mechanism by expressing the obtained time dependences through the phase coordinates. The proposed algorithms can be used to select the most effective structure of the electric drive control system of the excavator. Their use will reduce the dynamic loads, the level of elastic oscillations, increase the efficiency, and reliability of excavators.

N. K. Kuznetsov, I. A. Iov, A. A. Iov
Damping Ratio and Natural Frequency of Dynamic System in Milling

The problem of the machine tool stability in metalworking has existed since the first machine tool was created. Stability plays an important role in investigations dedicated to machining quality improvement, wear decrease, and, on the other hand, productivity increase. The identification of dynamic parameters such as modes, damping, and stiffness is a part of a stability problem. There are two groups of techniques to find the dynamic parameters: experimental modal analysis and operational modal analysis (OMA). In this study, OMA is used to identify the dynamic parameters of the system in milling. Responses (accelerations) are stored via three-axis accelerometer mounted on the spindle. Furthermore, power spectral density matrix of output responses is estimated. The estimation of natural frequencies and damping ratios is based on the analysis of a power spectral density matrix. A simulation model of milling is created, and some experimental tests are done to verify the suggested approach. The results are discussed as well.

K. Yu. Kravchenko, S. S. Kugaevskii, M. P. Zhuravlev
Models of Fatigue Fracture Under Cyclic Loading Pistons of Internal Combustion Engines

The crack on the piston under cyclic loading is the result of repetitive elastic and plastic deformations distributed unevenly throughout the volume. The microcracks from fatigue occur in repeated elastic and plastic deformations in the individual parts or sections throughout the volume of piston, that is, the precursor of cracks. However, a piston with a microcrack can work practically all the resource if there is no crack propagation. The crack creates its own stress field which is determined by the stress intensity factor characterizing the stress concentration at the crack tip and depends on the load, forms of a detail, crack size, and the anisotropy of the material. For the analytical description of the crack growth rate, it has been proposed more than 60 formulas and they are all based on the fact that all processes occurring at the crack tip and the rate of crack growth of the number of cycles depend on the stress concentration factor. The magnitude of the stress intensity factor allows one to judge about the stability or instability of cracks. The crack is called stable if it is not growing or its growth is linearly dependent on the load. When you select the corresponding operating mode of the engine, the crack on the edge of the combustion chamber of the piston may not develop and this way you can ensure that the crack has not increased its size. The crack would be unstable if its distribution only slightly depends on the load.

A. N. Gots
Investigation of Units Condition of Rotor-Type Milling Machines Based on Vibration Analysis

The application of methods and tools, spectral analysis of units, and mechanisms of production equipment in various industries makes it possible to determine their actual condition with sufficient probability which significantly reduces the occurrence of an emergency stop of equipment. Diagnostic information on the crusher support condition was obtained with the help of special equipment and technical devices for vibration recording. The calculation of natural frequencies of the crusher vibrations according to the calculated dependences was preliminary carried out for effective diagnostics. A defect was found as a result of regular monitoring of the rotor-type crusher through a system of predictable maintenance. The monitoring interval was 10 days, and as the defect developed, it was reduced to one day. The study and analysis of vibration spectra made it possible to determine the wear degree of outer and inner rings of the rolling bearings. The results of diagnostics made it possible to ensure the priority preparation of reserve elements of the bearing support, and it was timely replaced.

V. Yu. Ovsyannikov, A. I. Klychnikov, A. V. Sharov
Mathematical Modeling of Wear of Cutter on Back Edge by Taking into Account Beating and Kinematic Perturbations

The study of the wear of the cutter on the back edge with the turning process by taking into account the beating and the kinematic perturbations on the basis of mathematical simulation or mathematical modeling of the wear is provided. The basis of the wear modeling assumes the concept of its link between the work and power of the irreversible transformation in the contact area of the tool back edge and detail. For this purpose, the Voltaire integral operator of the second kind regarding the phase trajectory of the power of the irreversible transformation to the implemented work is used. The trajectory of the power to the work is determined on the basis of the performed model and depends on the structure and the parameters of the dynamic model of the cutting system as well as the beats and the kinematical perturbations. The example of the dependence wear on the beats parameters is presented.

V. L. Zakovorotny, V. E. Gvindjiliya
Determination of Critical Speed of Rail Vehicle as Mechanical System with Nonlinear Constraints

The article considers approaches to the determination of the critical speed of the rail vehicle which is the minimal speed along the straight flat part of the way with constant vibrations of curved movement of rail vehicle having an autovibrational character. As a result of the analyses of the existing approaches to the evaluation of motion stability of a rail vehicle as a mechanical system with nonlinear constraints, the authors introduce an original method to determine the critical speed based on the results of imitational modeling of a freight car. The article contains theoretical approaches to the development of the method introduced, analyzes processing and appearance of autovibrations of curved movement of a rail vehicle, and introduces the developed method of evaluation of critical speed for a rail vehicle with imitational modeling of the movement of a freight car as a mechanical system with nonlinear constraints. The method described in the article allows making a preliminary evaluation of the critical speed value within the stage of rail vehicle design as well as evaluating the influence of some constructive parameters of a technical realization of rolling stock units within different stages of designing and in the process of a rail vehicle life history which allows cutting the economic expenses within the stage of freight car designing and traffic safety increasing.

A. N. Davydov, A. V. Smolyaninov
Influence of Contact Area of Additional Elements on Frequency Spectrum Splitting in Cylindrical Shells

Thin circular cylindrical shells are widely applied in various industries. Sometimes, due to structural, operational, and strength requirements, special patches are attached to the shell construction in designs of aviation, rocket, and space technology. The article examines the influence of flush contact area of the added mass on basic frequencies and flexural modes of a thin circular cylindrical shell. The spectrum when the mass added to a shell could be considered lumped mass is identified. It is demonstrated that resizing additional element contact area significantly influences base frequencies. The reduction of a contact area of the added mass results in a noticeable drop of the lower splitting basic frequencies of shell oscillation. A drop in high frequency, possibly substantial, is associated with the extended contact area. A nonlinear relationship between a contact area of the added mass and basic frequency of shell–weight system is defined. Oscillation modes bear a resemblance to conjugate flexural sinusoidal and cosinusoidal forms; however, more complex (ambiguous) oscillatory modes are distinguished at supreme oscillation frequencies. A fundamental dependence of shell geometric characteristics bearing the added lumped mass on lower splitting basic frequencies is calculated.

S. V. Seregin
Selection of Rational Technological Modes and Parameters of Underwater Waterjet Cutting

The possibility of applying the acoustic emission method for optimizing the technological modes and parameters of underwater waterjet cutting is considered in the article. It is concluded that the creation of a universal technological equipment that allows cutting, segmenting, perforation, and cleaning underwater structures is an urgent scientific and technical problem. As a result of the series of experiments, it was shown that the acoustic emission method can be effectively used to monitor and control the procedure of materials’ processing when performing various operations using unmanned underwater robot manipulators. Graphic dependencies connecting the amplitude values of the received acoustic emission signal on the underwater cutting process’s time were obtained. The schemes for conducting all experiments’ stages and used technological equipment are presented. It was found that the method of acoustic emission makes it possible to determine the moment of material’s piercing by a waterjet stream for subsequent transition to the process of hydrocutting along a predetermined path cutting or segmentation. In conclusion, the article gives the analysis of the results of experimental studies, guidelines and shared insights, and prospective research tasks.

D. R. Mugla, A. L. Galinovskiy, N. V. Kobernik
Voxel and Finite Element Modeling of the Ceramic–Polymer Composite Panel for Ballistic Impact Description

Orbital object protection against micrometeorites and orbital garbage may be realized using flexible protective panels made of polymer matrix and ceramic grains. The best protection may be performed using grains of optimal size, specific grains volume content, and appropriate materials. In the view of this, development of parametric FE models with changeable parameters is an actual problem. The adequate description of a panel composite structure is an important modeling item. Composite micro-modeling with the description of each ceramic grain provides the most adequate results. Grains scanning and following image rasterization are used to describe a composite structure instead of abstract grains modeling. The application of voxel modeling and set algebra provides the modeling of an arbitrary composite structure. Plastic kinematic material model is used as a rather simple and adequate to minify computational complexity. Model parameters have been selected using experimental data and applied to describe penetrator impact on composite panel. The research has proved the feasibility of such modeling procedure.

E. I. Shchurova
Common Problems and Prospects of Crankshaft (Eccentric) Machinery Usage in Sawmilling

The article draws attention to the evolution and applying of crankshafts sawing machines with a rotary-translational motion cutting. We analyzed the kinematics of the cutting tool. The comparative analysis of cutting modes and productivity of crankshafts sawing machines are given. The problems associated with the removal of chips from the cutting zone are analyzed. It is proposed for the crankshafts sawing machines to spread a group of saws along two planes. According to the developers of crankshaft sawing machines with rotational–translational motion of the tool, these machines should replace gang saws of the second row, as well as circular and band re-saw machines. However, comparative performance analysis of the crankshaft sawing machines showed that they are unable to compete against gang saws, not to mention the multi-blade circular re-saw machines. Thus, it is clearly seen that today crankshaft sawing machines with rotational–translational movement of cutting have a number of the unresolved technical problems and do not have technological advantages over existing types of the sawmill equipment.

A. A. Kondratyuk, V. K. Shilko, A. A. Klopotov
Drill Bit Self-oscillation in Cutting

The paper analyzes the dynamics of drilling done with twist drill bits, and its dependency on the feed rate and rotation speed of the cutter. The analysis enables us to find the fundamental rules of how to control metal machining process systems. Depending on what such control might be needed for, study results could be used to make such control algorithms that help achieve and maintain the required drilling system quality. The analysis has revealed the regions of various tool motion types in the plane of cutting parameters (drill bit feed rate and rotation speed). We have found out that in a dynamic drilling system, the tool has three regions of motion: stable motion, unstable motion, and self-oscillatory motion. By choosing such cutter feed rate and rotation frequency values that belong to this or that region, one can control the drilling process parameters. High quality of machined hole surfaces is ensured as long as the feed rate and the rotation frequency are in the region of stable motion. Both values being in the region of self-oscillatory motion results in the fragmentation of chips, which makes the entire process more efficient for preparatory operations. Of course, the entire drilling process becomes more reliable as long as the feed rate and the rotation speed of the drill bit do not go to the unstable motion region. For more complete results, drilling dynamics analysis was complemented with analytical methodology and computer simulation.

V. S. Bykador
Using Local Coordinate Systems for Dimensional Analysis in the Machining

The article considers the implementation of the attached coordinate systems for machining at CNC machines. The main objective of this study is to suggest the improvements of processing accuracy. The problem arises when the machinable surface does not belong to a technological base. We offer the method based on preliminary measurement of workpiece dimensions. Further, the coordinate value enters into a CNC unit. The NC program uses the local coordinate systems, which are linked with measured dimensions of selected surfaces. In this case, the machining accuracy does not depend on errors connected with previous processing stages. Local coordinate systems can be effectively used for machining “rotary body”-type components at turning CNC machines or for machining conditions of box-like parts at milling CNC machines. We also offer the special device for adjustment “0” point outside a machine tool. As a result, the proposed method allows for a dimension chain shortening and accuracy improving.

S. S. Kugaevskii, V. N. Ashikhmin
Research of Nature of Interaction of Fuel Spray with Wall of Combustion Chamber of Overload Diesel Engine on Unique ‘Injection’ Research Installation

This paper provides the results of experimental research of visual development of diesel fuel spray and its interaction with the wall of combustion chamber for the regimes of an overloaded transport diesel engine. Studies are performed in a constant volume chamber using a unique ‘Injection’ research installation with colour high-speed video recording of the injection process. The analysis results show that the initial profile of the piston combustion chamber does not provide free development of the reverse-flow zone of the fuel spray after its collision with the combustion chamber wall, so the initial profile needs to be changed. To prove the efficiency of such measures, motor tests were performed for a one-cylinder diesel engine with the cylinder’s diameter of 150 mm, piston stroke of 160 mm, and also equipped with an air compressor at crankshaft speed of 2000 min−1. Two variants of piston structures, with an initial combustion chamber and a test one, were studied. The results of experimental research for a one-cylinder diesel engine show that the piston with the test combustion chamber in the whole studied range provides the improvement of fuel efficiency by 3–5 g/kW * h as compared to the initial combustion chamber without increasing of thermal and mechanical intensity which confirms the results of non-motor research.

I. O. Lysov, S. S. Nikiforov, E. B. Ryzhuk
Numerical Simulation of Conjugate Heat Transfer in Non-regular Mode of Cooling High-Temperature Metal Cylinder by Gas–Liquid Medium in Circular Channel

The results of the numerical modeling are presented for conjugate heat transfer in the non-regular mode of cooling a high-temperature metal cylinder by a gas–liquid medium in a horizontal circular channel. The results have been obtained on the basis of the two-dimensional mathematical model of the conjugate heat transfer of an unsteady gas–liquid flow and a metal cylinder taking into account the cooling medium flow symmetry relative to the cylinder longitudinal axis. The differential equation system is solved by the control volume approach. The flow field parameters are calculated with the use of an algorithm SIMPLE. The Gauss–Seidel method with under-relaxation is used for the iterative solution of the linear algebraic equations. The calculations are performed with the help of the mesh with a convergent profile on the boundaries ‘metal cylinder-liquid’ and ‘liquid-outer metal ring’ for the liquid and metal. The system of heat-mass-transfer balance at the evaporation is controlled on the basis of the energy model of heat balance. The calculation results have been obtained for the heat transfer parameters at cooling the high-temperature metal cylinder with the laminar gas–liquid flow with consideration of evaporation in the liquid. The intensity of the variation of the conjugated substance temperature, the gas–liquid flow velocity, the vapor volume concentration in the liquid flow, and the specific mass velocity of evaporation in the liquid depending on the cooling time are analyzed.

S. S. Makarov, V. B. Dementiev
Amplitude–Frequency Method of Control of a Mobile Drilling Machine with Hydraulic Drive with Dependent Tool Advance

The paper explores an innovative method of control of a mobile drilling machine hydromechanical system of the working motions. This method is used to create the dependent hydraulic drive tool advance on load from the main motion. The method is based on the principle of conversion of an amplitude–frequency signal by pressure generated by a hydromechanical multiparameter sensor and its transformation by the hydraulic control circuit into displacement of the control cylinder of the feed drive hydraulic motor. The results of the computational experiment confirm the effectiveness of the proposed method of volumetric control in comparison with the previously used throttle control for dynamic and energy characteristics by 23–40% for the considered mobile drilling machine.

S. V. Rakulenko, V. I. Grishchenko, M. S. Poleshkin
Control of Damping Process in System of Vibration Isolation

The results of solving the problem of finding the optimal synthesizing control function of the damping process in the vibration isolation system are given. It is established that the optimal control determines the intermittent damping process. The damper is activated when the sign of the object’s speed changes and is switched off when the object’s displacement sign is changed. The results of the simulation of dynamic processes in a controlled system of vibration isolation indicate that intermittent damping eliminates resonant phenomena and provides a monotonic decrease in the dynamic coefficients with increasing frequency of power disturbance. In this case, the transient processes decay within the same period of forced oscillations.

V. Chernyshev, O. Fominova
Estimation of Energy Efficiency of Oscillations of Rotors on Radial Fluid Film Bearings

The following parameters have the most influence on the dynamics of a high-speed turbomachine’s rotor system: mass and stiffness distribution of a rotor; damping properties of the materials of rotor’s elements; location of bearings, sealings, and dampers; type, design, and operational conditions of bearings, sealings, and dampers; mass and inertia characteristics of machine’s housing; and operational conditions of a turbomachine itself. It should be noted that the presence of fluid film bearing complicates the dynamic analysis. It is thus a quite urgent task to search for some rational parameters when a rotor system is under design and preliminary calculation, which in many cases leads to the problems of an optimal parametric design. One of the main yet controversial problems of parametric design in the field of rotor system dynamics is the determination of quality indicators for a particular case of a rotor system. The present paper proposed a criterion based on the efficiency of rotor system’s input energy. The analysis of a number of parameters’, e.g., values of constant external forces (rotor’s mass), varying external forces (imbalance), and types of bearings, influence on this criterion has also been carried out.

S. Majorov, L. Savin, A. Babin
Method of Investigating Dynamic Operating Modes of Electrohydraulic Drive Systems with Movable Boundaries of Working Fluids

The paper provides a methodology of the difficult hydropower-driven systems equipped with primary energy sources of two types: explosive motors and the electric motors operating under trying conditions of maintenance. The latter, alongside with hydropower-driven systems, are modeled as uniform heat-electro hydromechanical systems, optimum control with which one can carry out on the basis of a mechanotronic approach and a principle of a maximum developed by L.S. Pontrjagin. The method for investigating dynamic operating modes of electrohydraulic drive systems with movable boundaries of operating fluids was described. The method is original as it allows one to calculate dynamic operating modes of the abovementioned systems in the cases when fluids of these systems have movable boundaries of the following type: “fluid–gas” or “fluid–solid” (“fluid–piston”). The description of engineering, physical, and mathematical models of the investigated processes was presented.

A. I. Ozerskij, N. A. Tseligorov
Self-synchronized Controlled Vibration Drive with Automated Oscillation Parameters Monitoring System for High-Tech Equipment

This article raises one of the important problems of the high-tech industry—aviation and rocket and space industry. The development of modern aircraft is accompanied by stringent requirements for resistance to the dynamic loads acting on them, as well as for the utilization of the fragile components included in the design of the aircraft. Complexity, in the process of utilization of fragile components, arises when certain requirements are meted out to geometrical shapes and sizes. Complexity, in the process of utilization of fragile components, arises when certain requirements are meted out to geometrical shapes and sizes. The most striking examples of fragile components being disposed of are solid propellant charges. In addition to the problem of recycling fragile components, aircraft are subjected to vibrational loads throughout the life cycle. The moment of take-off of the aircraft and the change in flight regimes, as well as the separation of stages are accompanied by intense vibration in a wide range of frequencies associated with a high level of overload. The main purpose of this article is to create a vibration drive that can be used in various technological operations, ranging from vibration testing of aircraft structures to the utilization of fragile LA components. In the course of research, a fundamentally new method for exciting synchronous oscillations in vibration drives was developed. To control and maintain the specified vibration parameters, an automated control system has been developed that allows one to perform vibration testing of the structure under various vibration modes that can be laid in the program part of the controller.

S. V. Sergeev, Yu. S. Sergeev, A. V. Kononistov
Analysis of Effect of Internal Pressure on Natural Frequencies of Bending Vibrations of a Straight Pipe with Fluid

Three computational methods were compared to evaluate the correctness of determining the natural frequencies of bending vibrations of a straight pipe with a fluid. Natural frequencies of bending vibrations of a pipe were computed by the finite element method using ANSYS Mechanical, module Modal Acoustic, and ACT Acoustic. Using ANSYS Mechanical, the estimation of changes in the internal volume of a straight pipe is received depending on the internal pressure. To solve this problem, Shell and Solid elements for the pipe and Solid, Fluid, and Hydrostatic Fluid for fluid are used. Using ANSYS Mechanical, the natural frequencies are obtained for the pipe with the fluid depending on the density and internal pressure. In this case, the density of the fluid is taken into account in the equivalent density of the tube material. In accordance with the results of calculations, the paper proposes an analytical dependence of the first natural frequency of the tube bending vibrations and fluid density, taking into account the internal pressure and the change in the internal volume. The obtained dependences makes it possible to determine with high accuracy, the density of the fluid by the magnitude of its natural frequency and internal pressure, including taking into account the change in the internal volume of the tube. As it is discussed in the paper, the computational method can be extended to a curved tube Coriolis meter in calculating the fluid density based on the experimental natural frequency.

A. S. Khoruzhiy, P. A. Taranenko
Experimental Modular Unit for Testing Nodes of Air Suspension with Combined Amortization

In Volgograd State Technical University, on the basis of chassis dynamo, an experimental modular unit was created for testing the load on air suspension in various regimes and with various combinations of amortization nodes: hydraulic shock absorber, air damper, inertial friction damper, and dynamic absorber. The unit allows determining the characteristics of elements and vibration isolation qualities of suspension as a part of a single-support oscillating system in view of imitation of sprung and unsprung weights of a car per one wheel. The program of tests envisages determining the characteristics of tested elements separately and vibration isolation qualities of air suspension with different combinations of damping units during setting, the power and kinematic influences on suspension in a wide range of frequencies that appear during car’s movement. As a result of the tests, optimal parameters of combined amortization of the studied air suspension are determined which ensures a high level of vibration isolation of the car in the whole exploitation range of frequencies.

V. V. Novikov, D. A. Chumakov, I. A. Golyatkin
Calculation of Kinematic Characteristics of Internal Combustion Engine Valve Gear

The technique of the Internal Combustion Engine (ICE) valve gear kinematic characteristics calculation in the case of numerical differentiation of tabular predetermined tappet movement law is submitted. The authors proposed and implemented a method of converting these characteristics when using the same Cam for different valve gear kinematic schemes. Based on the methods of calculation of the motion law of the follower, the authors obtained the characteristics of the timing and conversion of data during the transition from one kinematics to another developed in a computer software, which is included in the software complex for synthesis of the characteristics of the valve timing. Their use allows one to identify resources for improving the timing mechanism of an internal combustion engine.

A. V. Vasilyev, Y. S. Bakhracheva
Impact of Design Parameters on the Efficiency of Loading Organs with Gathering Stars of the Roadheaders

Modern roadheaders of selective action are mostly equipped with loading organs with gathering stars, which have simpler drive structure and increased reliability. On the one hand, the process of traffic flow formation by loading organs with gathering paws is well studied, and on the other hand, the variety of its designs suggest of the manufacturers’ attempts to find empirically optimal parameters of loading organs of road headers. As a result of experimental studies performed at SRSPU (NPI), Russia it has established that under certain conditions a large-lump material of the pile may be converted into a fluidized state, which reduces the load on the shaft of gathering star. In addition, when designing of loading organs of road headers, it is advisable to choose power capacity as an objective function, and take additional criteria into account: angles of gathering star rays “meeting” with conveyor and the front edge of the pile. The analysis of built Power capacity–Performance diagram showed that an increase in the number of rays of gathering star reduces the influence of other parameters of loading organ. Thus, for a multi-beam gathering star, shape of rays and their setting angle cease to play a decisive role in the formation of loads in the drive, as the shape of gathering paw for similar loading organs, and good discharge capacity on receiving conveyor of the road header shall be ensured.

A. V. Otrokov, G. S. Khazanovich, N. B. Afonina
Virtual Prototyping Experience of the Coriolis Flow Meter

The subject of the study is the selection of the parameters of the model for finite element analysis (FEA) of the Coriolis flow meter. Based on the comparison of the results of calculations with previous experiments, it is shown that the built model can be used as a virtual prototype of the Coriolis flow meter when working with a single-phase liquid. Particular attention is paid to the detected danger of multiple overestimations of the dissipative properties of the model of the coupled nonlinear oscillatory system “elastic tube—liquid flowing through it”, built using the Two-Way Fluid–Structure Interaction (FSI) technology. It is shown that the overestimation of the dissipative characteristics leads to a distortion of the shape of the resonance oscillations, which makes such a model unacceptable for estimating the phase relations for both force and kinematic excitation. The settings of the design model allowing to obtain an idealized design case of the Coriolis flow meter without energy losses are given, and thus, they help to isolate the component of the sensor output signal (phase shift), which is caused solely by the flow of liquid.

V. A. Romanov, V. P. Beskachko
Theoretical Foundations of Optimal Two-Step Control of Suspension Stiffness of Transport Vehicle in Oscillation Cycle

The article dwells upon the issues of control over suspension stiffness of transport vehicle in the oscillation cycle. This article describes the methods of stiffness change for suspension and identifies two principal schemes of two-step stiffness change for the suspension: a suspension with constant step stiffness and a suspension with variable step stiffness. Mathematical models of suspensions with a two-step stiffness control in a single-mass oscillating system were developed for each of the two principal schemes of stiffness control. Having employed the maximum principle of L. S. Pontriagin, the algorithms for the optimal suspension stiffness control were determined. In particular, it was found that, when the oscillating system is unbalanced with the subsequent absence of the external force and kinematic action, any stiffness switching, even chaotic one, results in a decrease in the motion amplitudes of the sprung mass and oscillation damping. The optimal control algorithm in case of kinematic disturbance of the oscillating system is an algorithm at which the activation of a suspension step with a higher stiffness occurs during the change in the direction of suspension deformation, and the system switches to the lower stiffness during the change in the direction of the sprung mass motion.

K. V. Chernyshov, I. M. Ryabov, A. V. Pozdeev
Potential Vibration Isolation Qualities of Suspensions with Two-Step Stiffness Control in Oscillation Cycle

The article dwells upon the detection of potential vibration isolation qualities of suspensions with a two-step stiffness control during the oscillation cycle using the example of a single-mass oscillating system. There are two principal schemes of two-step stiffness change of a vehicle suspension: a suspension with constant step stiffness and a suspension with variable step stiffness. A comparative study of vibration isolation qualities of a single-mass oscillating system with a two-step stiffness control, which corresponds to the abovementioned principal schemes was conducted. As a result of the conducted study, the optimal parameters of suspensions were detected, which ensure the stoppage of the sprung mass during a half of the oscillation cycle when the system goes out of the state of equilibrium and when there is no kinematic and dynamic disturbance effect. Besides, the optimal parameters of suspensions were further detected, which ensure the minimum deviations of the sprung mass from the neutral position corresponding to the soft suspension at the kinematic sinusoidal input. It was found that the suspension which is based on the diagram of two-step stiffness change of a suspension with constant step stiffness, provides for higher vibration isolation qualities, when used in a single-mass oscillating system as compared to the conventional uncontrolled suspension and suspension which is based on a two-step stiffness change diagram of suspension with variable step stiffness. The issue of high-frequency oscillation of a springing element as a result of a switch from higher stiffness to lower stiffness was noted.

K. V. Chernyshov, I. M. Ryabov, A. V. Pozdeev
Fatigue Life Prediction of Track Link of a High-Speed Vehicle

The paper presents a methodology for calculating the fatigue life of tracks of a high-speed tracked vehicle. The methodology includes computer simulation of motion of the machine on the road, calculation of loads acting on the tracks of tracks, stresses in the most stressed areas of the tracks, and prediction of durability by the criterion of fatigue failure. In the simulation of motion, the dynamic properties of the projected machine and the typical operating conditions in different climatic conditions are taken into account. The characteristics of loading are determined by the results of full-scale field tests. The maximum stresses in the tracks occur under the action of random loads from the ground. Ground is regarded as a Winkler half-space with randomly distributed elastic elements. To calculate the stresses in the most loaded zones of the tracks, a technique based on the principle of independence of the action of forces and the use of the finite element method is proposed. In different loading cycles, the relationship between the components of the stress tensor in the most stressed zone is different. The loading of the track is multiparameter. Therefore, a special method was used to calculate the accumulated fatigue damage. The article presents the results of using the proposed methodology for predicting the fatigue life of tracks of tracked transport vehicles.

A. A. Abyzov, I. I. Berezin
Hydroelastic Response of Three-Layered Plate Interacting with Pulsating Viscous Liquid Layer

The problem of longitudinal and bending oscillations of the sandwich plate interacting with the pulsating viscous fluid layer was investigated. The three-layered plate with an incompressible filler was considered. The model of viscous incompressible fluid was chosen to study viscous fluid dynamics. A mathematical model of the investigated mechanical system consists of dynamic equations of the three-layered plate with an incompressible filler, the Navier–Stokes equations and the continuity equation for a viscous incompressible fluid. The no-slip conditions and pressure coincidence at the edges with pressure in the surrounding liquid were selected as boundary ones. The plane problem of hydroelasticity was considered. We investigated the regime of steady harmonic oscillations. The dimensionless variables and small parameters were proposed to solve the problem. The solution of the hydroelastic problem was carried out by the perturbations method using the proposed small parameters of the problem. As a result, we obtained the linearization problem of hydroelasticity. The elastic displacement of the plate and the hydrodynamic parameters of the fluid were founded.

V. S. Popov, L. I. Mogilevich, E. D. Grushenkova
Experimental Study of Spark-Ignited Two-Stroke Heavy Fuel Engine

There is a growing interest in spark-ignited engines, which could operate on heavy fuels (jet and diesel fuel). The explanation is in good power to weight characteristic of spark-ignited engines unlike diesels. At the same time, the main disadvantage of engines with spark ignition is high fuel consumption under high loads using heavy fuels. This explains the necessity of applying low compression ratio in comparison to gasoline analogues. This study describes the operation process of 2-stroke spark-ignited piston engine, which can conserve the compression ratio of the base gasoline engine (10.5) when operating on heavy fuels. It is explained by using a compressed-air atomizer in combination with spray-guided concept. Ignition is carried out via a standard single-spark automotive ignition system. It is shown that the experimental engine is able to run on heavy fuels without knocking in all base engine load ranges. In addition, the unthrottled control is possible in this concept. The cold start investigation was carried out. The experimental engine is successfully started at an ambient temperature up to −20 °C.

M. D. Garipov, D. R. Rezvanov, R. F. Zinnatullin
Application of Experimental Modal Analysis for Identification of Laminated Carbon Fiber-Reinforced Plastics Model Parameters

Modal characteristics (natural frequencies and vibration modes) estimation is a common way to avoid resonance vibrations in constructions. It requires reliable data about mechanical properties of the material. In the case, when the polymer composites’ determination of such characteristics is difficult (in comparison of isotropic materials), because of a greater amount of elasticity characteristics and their dependency on wide range of structural and technological factors. Also, most of the literature and open sources contain controversial data about composite material properties, and in case of crucial constructions calculations, it would be better to perform an additional experimental identification of these properties. The aim of this paper is to create elastic vibration model parameters identification method for polymer composites using experimental modal analysis. The object of research is laminated carbon fiber-reinforced plastic based on a full strength carbon material widely used in aviation. An experimental determination of natural frequencies and corresponding vibration modes was performed using 3D scanning laser vibrometry. Finite-element analysis was used for numerical determination of modal characteristics. The material model used in calculations is a laminated composite structure with orthotropic, linear, and elastic layers. Identification of parameters was performed as a minimization problem of discrepancy between natural frequencies for corresponding vibration modes obtained numerically and experimentally. The problem solving was performed using a quasi-random search method. The proposed method can be recommended for material properties determination required for a modal analysis of polymer composite structures.

M. Sh. Nikhamkin, S. V. Semenov, D. G. Solomonov
Reducing the Level of Vibration in Two-Stream Spur Gear

Dynamic processes in spur gears with a split stage consisting of two identical parallel gear pairs are studied. Multistream transmission in addition to a distribution of transmitted energy in several paths provides a great scope for control over these streams and, consequently, the use of a multistream transmission offers an alternative to other familiar methods to reduce the level of vibrations. The dynamic lumped-parameter gear model incorporates the effects of a time-varying mesh stiffness due to the variation in the number of teeth pairs being simultaneously in meshing. The model is formulated to analyze the spur gear parametric vibration under a regime of steady-state motion. Numerical studies were employed to examine the effects of the phase shift between parallel gear pairs on the vibration in the system. The comparisons between the results from multistream in-phase and out-of-phase transmissions revealed differences in the gear responses, especially in the zone close to the zone of parametric resonance. It can be used for detuning from parametric resonance.

V. A. Kryukov, A. V. Plyasov
Analysis of Application of Pre-screwed Auger Wheels for Operative Increasing of Throughput Capacity of Oil Pipelines

In the paper, the application of a pre-screwed wheel of centrifugal main oil pumps is observed. The pre-screwed wheel serves as a backup pump for the main impeller and creates a small head. In this case, the cavitations reserve of the main unit is significantly reduced. The increase of throughput capacity is due to two factors: a slight increase in pressure after the station, as well as a significant reduction in the pressure before the pumping station. The application of a pre-screwed wheel is proposed for the operative increase of a throughput capacity at a small value. Economical comparison of the following methods of increase of throughput capacity is made: (1) use of a frequency-controlled drive (2) use of anti-turbulent additives (3) reduction of the settings at the entrance of stations with the help of pre-screwed wheels (4) selective repair of sections (5) restoring the pipeline capacity on the basis of determining the actual remaining life of pipelines without selective repair of sections. It is considered that the application of a pre-screwed wheel is characterized by low economic costs and small time of implementation and this method is perspective in oil industry.

Vitaliy Surikov, Yuri Lisin, Anvar Valeev
Mathematical Model of Cut Layer at Intensive Profile Milling of Workpieces

The tendency of development of mechanical processing of materials is considered, and the continuous increase of cutting and feeding speeds is noted during the removal of stock. The increase in cutting modes by one or two orders leads to the inadequacy of the existing mathematical models of the parameters of the cut layer, and to a significant discrepancy between the calculation results and the experimental data. To improve the design of intensive technological processes, new mathematical models for calculating the parameters of the cut layer, suitable for cylindrical, profile milling of wood, are developed in the article providing the adequate results of calculations regardless of the level of the assigned cutting modes. The graphs of the dependence of the parameters of the cut layer on independent factors characterizing the intensive milling modes are presented, they are necessary for the development of intensive technological processes of cylindrical and profile milling.

V. G. Gusev, A. A. Fomin, V. A. Saldaev
Assurance of Accuracy of Longitudinal Section of Profile Surfaces Milled at High Feeds

The article considers the process of profile milling of extended surfaces with shaping cutters and independent factors determining the dominant influence on the optimization parameter as well as the deviation of the longitudinal section profile of the product. One-factor experiments were conducted on the basis of which the operating conditions of the technological system were further determined under which the processing process proceeds steadily with a minimum level of vibration. Under these operating conditions of the technological system, multifactorial experiments were performed. The multifactorial experimental model of the optimization parameter as a function of the elements of the cutting mode was obtained on the basis of which the deviation of the profile of the longitudinal section was simulated in a wide range of values of the independent factors of the profile milling process. The statistical processing of the data of the planned and realized multifactor experiment was carried out, the multifactor model was tested for adequacy and its graphical interpretation was presented which allowed obtaining the scientific data necessary for the well-founded construction of intensive operations of workpiece profile milling.

A. A. Fomin, V. G. Gusev, A. R. Sadrtdinov
Dynamics of Rotary Milling According to Group Scheme of Obtaining Discontinuous Chips

The forces, oscillations, or vibrations arising in the process of cutting must be taken into account, when optimizing any process operation or process. One of the high-performance machining processes is rotary cutting. However, the presence of an additional rotation of cutting elements decreases the rigidity of rotary tools, increases the variability of the operating forces, which require studying vibration dynamic phenomena at rotary processing. Rotary milling, being an intermittent cutting process, increases the possibility of obtaining discontinuous chips. The cutting tool operation according to the group cutting scheme is also used for efficient chip breaking. The measurements were carried out using a dynamometer and a spectrum analyzer. The obtained results reflect the dynamics of the rotary milling process and qualitatively coincide with the dynamic phenomena at conventional face milling and rotary turning. However, at the same time, we revealed characteristic features predetermined by the operation of the toothed cutting element according to the group cutting scheme.

S. D. Smetanin, V. G. Shalamov
Modeling Hydrodynamic Processes in the Vortex Generator

The vortex heat generators are known as installations that allow converting the liquid stream energy into heat. Currently, there are many manufacturers of heat generators with various declared parameters and characteristics. The authors interpret various scientific hypotheses explaining the hydrodynamic processes occurring in the heat generator, however, only a small number of real experimental studies on this subject representing of great interest are in free public access. This article is devoted to the actual issue of processes modeling the vortex high-pressure fluid flow in the constant volume circuit. The authors consider the physical and numerical modeling of these processes occurring during the fluid flowing in closed channels with throttling of the flow section and high-speed flowing through tangentially directed nozzles in the special chambers. At the same time, thanks to the organization of a swirling flow in special chambers in a closed circuit, an intensive growth of the working fluid temperature is observed; it allows the vortex devices of this type to perform the functions of heat generators. The equations describing the cavitational two-phase fluid flow and the numerical simulation results of the flow in the heat generator using the software complex ANSYS are presented in the article.

R. R. Kalimullin, T. A. Volkova, A. R. Valeev
The Substantiation of Necessity to Modernize the Gas Pipelines Gas Cooling System

The large diameter main gasline is a high danger level production facilities. Main gaslines are subjects of increased requirements of safe operation. The feasibility of emergency increases with the course of exploitation time. Keeping a gas transmission system in proper working order with ensuring the safety of the environment is a complex problem. Solving this problem requires to apply a multifaceted approach and conduct a detail analysis technical condition in facilities of pipeline system and operations which are proceeding in the process of gas transportation. In this article, it provided rationalization for the necessity to modernize the gas pipelines gas cooling system, taking cue from operation features, and thermal interaction large diameter main gaslines with soil. The usage of air cooling gas equipment with a variable frequency electric drive of the blower motor as a part of complex solvation temperature (thermic) condition stabilization problem of working pattern large diameter main gasline is considered.

Aliya Bakhtegareeva, Olga Mironova, Elvira Bakhtegareeva
Modeling Quasi-static Gait of a Person Wearing Lower Limb Exoskeleton

The paper presents the results of lower limb assistive exoskeleton walking modeling. The authors consider a new spatial model of human motion in an exoskeleton with 10 electric drives, which allows providing a stable walk with no crutches needed. The kinematics of quasi-static gait in frontal and sagittal plane is discussed taking into account the condition for stability of motion. Various types of trajectories of motion of the foot and a numerical simulation of the gait of the exoskeleton are presented. The trajectories of the center of mass of the walking exoskeleton with time function of each joint angle could be used to design a control system of a walking robot. The obtained results are employable to synthesize a digital control system for walking robots and exoskeletons.

A. Yatsun, S. Jatsun
Modeling of Thin-Walled Cylindrical Part Turning Process Dynamics

This article presents the method of chatter prediction in turning process using 3D diagrams of maximum and minimum vibrations magnitudes, cutting forces, and instantaneous chip thickness along the tool path. The 3D structural dynamic module includes a finite element model of workpiece and surface topography module, a dynamic cutting force prediction module. The gyroscopic effects are taken into the account. A numerical model simulating the turning process of thin-walled cylindrical workpieces for various spindle speed values is considered. The results of the modeling are 3D diagrams of maximum and minimum vibrations magnitudes along the tool path. The simulated results taking into account material removing, gyroscopic effects, and no effects are compared. The results of numerical simulations predict the chatter-free regimes of a turning process.

A. Koloskova, I. Kiselev, S. Voronov
Investigation of Controlled Vibratory Drilling Dynamics with Variable Velocity Feedback Gain

During drilling, swarf can block tool’s clearance channel and lead to a standstill of production job. That is why it is advisable to make a drill bit oscillate in the axial direction. The certain amplitude–phase relation guarantees chip breakage. One of the ways to ensure this kind of vibration is to include in the system of tool fastening the special elastic element, characteristics of which are chosen from conditions of axial self-excited vibration excitation in the technological system. It is appropriate to add the control response, which sustains the tool vibrations in a wide range of manufacturing process parameters. In this paper, the model of vibratory drilling dynamics with velocity feedback is given. The possibilities of setting velocity feedback gain as constant and periodical laws have been investigated. The relation between integral characteristics of vibrational process and these laws parameters have been plotted. It is shown that the vibrational characteristics in case the feedback gain is set as a periodical function cannot be achieved in any way if the feedback gain is a constant.

I. Ivanov, I. Pleshcheev, A. Larkin
Justification of Program for Accelerated Tests of Aircraft Auxiliary Gas Turbine Engine

This article presents a justification of the program for accelerated tests (ATs) of an aircraft auxiliary gas turbine engine (AGTE) which consists of a turbine, a compressor, a combustion chamber, a reduction gearbox, a DC generator (GS-12TO) and an AC generator (GT 4bPCh6), a fan, and other units. The AGTE is designed for air starting of aircraft main engines at aerodromes, for pneumatic supply for the air-driven devices in flight in case of failure of the primary power supply sources, for ensuring the AC and DC power supply for the onboard power system of the aircraft both on ground and in flight. The justification of the program for the ATs is provided with the account taken of the primary elements of the assemblies which determine the reliability and the service life of the AGTE: the nozzle vanes and the blades of the first turbine stage; the disks of the second and third turbine stages; the thrust and radial bearing of the turbocompressor rotor; the driving gear of the reduction gearbox; and the elements of the DC and AC generators. The modes and the duration of the ATs are determined for the longest load step of the AGTE in operation which includes the air bleed at the compressor discharge (Gab = 1.35 kg/s) and the electric power takeoff from the DC generator (NDC gen. = 12 kW) and the AC generator (NAC gen. = 33 kVA). The modes and the duration of the ATs determined in this article enable us to ensure the equivalence of the ATs and the long-duration tests (LDTs) (the equivalence is understood to be the equality of the damage rates of the primary elements of assemblies during the LDTs and the ATs).

A. S. Gishvarov, M. N. Davydov
Longitudinal Fin Effect on Effectiveness of Double Pipe Heat Exchanger

In this study, the authors conducted mathematical simulation on the double pipe heat exchanger in which longitudinal fin with the dimension of (2 * 3 * 1000) mm supported on the outer surface of the inner tube. This paper contains the benefits of this design on heat transfer between fluids flowing through the system and at the same time its effect on the heat exchanger effectiveness, which helped us to select the optimum design. A consistent computer program (ANSYS Workbench 15.0) was used in this study to show the behavior of the fluids inside of a heat exchanger, and the results are also obtained by the program.

Nail Farilovich Timerbaev, Omar Abdulhadi Mustafa Almohammed, Asaad Kamil Ali
Modeling and Dynamic Analysis of Adjustable Axial Flow Divider

The use of an axial divider as a part of the hydrostatic transmission makes it possible to realize the torque regulation of the motorized wheel due to pressure dynamics without increasing the flow of working fluid and also to simplify the control system. This paper is concerned with mathematical modeling and dynamic analysis of an axial adjustable volumetric flow divider. The model was developed using the equation of a flow divider’s section displacement, the equation of torque on the shaft of the flow divider’s section, and the equation of theoretical consumption of the divider’s section. The Runge–Kutta method of the fourth order with a fixed step was used to solve the equation. Transient dynamic characteristics were obtained for the cases of displacement changes of the divider section.

D. L. Karelin, A. V. Boldyrev, A. M. Belousov
Study of Combustion Stroke of Double-Chamber Explosive Gas Forming Device

The double-chamber explosive gas forming device is a kind of pulse punching unit. The device comprises a combustion chamber and an operating cylinder separated from each other by a piston, at the top of which an elastic disc is mounted. The stamping process is carried out by the pressure of the elastic disc due to the kinetic energy of the piston being accumulated during the explosion stroke. The piston is accelerated by the pressure of a high-temperature gas formed in the combustion chamber through the gaseous fuel mixtures burnout. The explosion stroke process was analysed on the basis of the equations of rigid body dynamics and thermodynamics. As a result, the regularity of the piston motion was determined, and the optimal ratios of the geometric parameters of the stamping device were found, ensuring an increase in its effective energy. It is established that the motion pattern of a piston depends essentially on the ratios of the flow bore section of an exhaust valve and the cross section of an operating cylinder. If this ratio is less than 0.07, the piston oscillates along the length of the cylinder, which is not acceptable for the stamping process. If it is greater than 0.1, the piston moves monotonously, continuously accumulating kinetic energy, which ensures the punching process. It is also established that the optimum ratio of the operating cylinder and the combustion chamber is within the range of 1.3–2.5.

A. Yu. Botashev, A. A. Musaev, R. A. Bayramukov
Influence of Elastic–Plastic Transformation of Mechanorheological Model on Impact Duration

To study dynamics processes, a mechanorheological viscoelastic–plastic model has been developed. It includes elastic, viscous, and plastic elements. Based on the experiments, a method designed to calculate the values of impact parameters was developed. A simplified model behavior was analyzed. It was assumed that under impact interaction, the model is viscoelastic–plastic since the beginning of the impact process, i.e., plastic deformations occur simultaneously with elastic ones. However, the experiments showed that at the loading stage, elastic deformations can occur as well. Under certain conditions, when stresses reach a yield point, plastic deformation occurs. The value of a control force for early development of plastic deformations can influence the duration and other parameters of the dynamic impact process. The experiments demonstrated that at the loading stage, the viscoelastic model becomes transformed into the viscoelastic–plastic one which increases the impact duration. It might be due to the fact that total deformations increase significantly owing to the plastic model component. As a result, the model motion value increases as well. Impact braking acceleration decreases, which leads to an impact duration increase. According to the results of the impact process research, the following conclusions can be drawn: the impact duration is influenced by the elastic–plastic transformation of the model. At the initial stage of plastic deformation, the force value is an important model control parameter influencing the impact duration and movement dynamics. The application of a more generalized model for solving practical tasks will help to increase research and impact interaction simulation accuracy and reliability.

V. Lapshin
Mathematical Modeling of Oscillations of the Associated Transport and Technological Complex with the Use of the Graph Theory

The work of technological complexes is connected with specific operating conditions, especially when moving on temporary roads and off-road conditions. A new model was developed for the analysis of production machinery dynamical oscillation under attachable equipment influence. The developed model was divided into simple modules, which allowed us to use the graph theory for modeling. A special structure was created for the oscillation model which allowed us to take into consideration the main vehicle movement parts, objects of internal impact, and attachable equipment influence. The most important idea of a coupling transport oscillation model was the center of mass modeling. This approach showed that the most important role in decreasing of oscillation decay time is suspension characteristics. Using mainly the experimental technique of proelastic suspension properties and coupling active nodes, you can minimize the machine body frame oscillation decay time. As the calculation shows, the oscillation decay time can be reduced by more than two times with simple adding of the second trailer unit. A modular modeling principle of complex dynamic systems allows solving complicated technological transportation systems with any structure. This approach allows us to predict complex dynamic systems behavior and take into consideration different types of external dynamic forces without expensive experiments.

E. Bazhenov, S. Buynachev, D. Chernyshev
Modeling of Seismic Processes in Buildings at Presence of Elastoplastic Seismic Insulators

The work is devoted to the problems of reducing the intensity of seismic impacts on multistorey buildings. It is known that the main difficulties in solving the problems of seismic isolation of buildings and structures lie in the field of creating mathematical models for the dynamic interaction of the “foundation-seismic isolation device-construction” systems and are largely due to nonstationary seismic processes. One of the most effective ways to reduce the level of seismic impacts on buildings is to equip them with special devices-seismic isolators, a successful method of implementation of which is the use of elastoplastic systems with a number of undeniable advantages. A technique for calculating the seismic effects of multistorey buildings equipped with elastoplastic seismic insulators is proposed; N. N. Davidenkov’s rheological model was used to numerically simulate the alternating loading. The modeling of dynamic processes is carried out by means of a mathematical description of the dynamics of two linear multidimensional subsystems that approximate the structures located under seismic insulators and above seismic insulators. The dynamics equations are formed on the basis of the D’Alembert principle. Horizontal seismic effects are considered. The presented technique makes it possible to determine the movements of the nodes of the system at any time of the seismic action specified in the form of a digitized seismogram. The above algorithm is implemented as a software module Proxima. The results of calculations are presented on the example of a model of a 24-storey building designed for building conditions in the city of Irkutsk.

V. I. Sobolev, E. V. Zenkov
Planning an Experiment in Assessing Altitude–Velocity Characteristics of Aviation Gas Turbine Engine

When fine-tuning aviation gas turbine engines (GTE), tests are carried out on high-altitude booths with imitation of engine operating conditions in high-speed conditions. Based on the test results, the high-speed characteristics of the GTE—the dependence of the thrust (R) and fuel consumption (GF) on the flight altitude (H) and rotor speed (n)—are constructed [the flight speed is kept constant (M = const)]. In order to reduce the material and time costs for carrying out the experimental study of the GTE, the tests are carried out according to a special planned experiment plan, which results in the construction of regression models of the type R = f (n, H), GF = f (n, H) (M = const) in the form of polynomials of the second order. The plans for experiments (PE) are selected from various sources of literature, for example, the catalogues of plans, etc. This article considers the methods for increasing the efficiency of PE by reducing the variance (d) estimation of parameters R and GF using regression models R = f (n, H), GF = f (n, H) and reducing the number of experiments (N) in PE.

A. S. Gishvarov, M. N. Davidov, A. V. Zyrianov
Damping Accounting in Calculating Problem of Thin-Walled Rod of Closed Profile

We investigated the natural oscillations of a thin-walled rod of a closed profile with allowance for damping by the viscoelastic model by the example of fixed-ended rod. We obtained differential equations of thin-walled rod oscillations, taking into account the internal friction of the material and shifts from bending and constrained torsion. The frequencies of both bending and torsional oscillations were determined. The calculation results are compared with the calculations in the SAE system and the results of the full-scale experiment. The obtained results can be applied for dynamic calculations of thin-walled structural elements, in particular, to prevent the destruction of structures when resonance phenomena occur.

A. Gavrilov, E. Poyarkova, N. Morozov
Application of Combined Technique for Chatter Prediction in 5-Axis Milling

The technologies used in machining have been recently developing in a rapid way. Higher quality requirements, workpieces complexity, and appearance of new poor machinability materials cause the need to improve the existing methods and create new ones. One of the main problems, which limits machining efficiency, is self-excited vibrations. Such vibrations are mainly caused by the regenerative mechanism of machining workpiece surface. The regenerative mechanism appearance causes the substantial deterioration of the machined surface, tool and machine units wear. This issue is far more important while processing compliant parts made of poor machinability materials, for instance, blades or bling of gas turbine engines. The verification of the calculation-experimental method, which has been designed by the authors and allows to predict self-excited vibrations appearance in the tool/workpiece system and set more efficient machining modes, was carried out. The verification of the method was conducted for the 5-axis machining of the aluminum blade of a gas turbine engine model as an example. The blade milling dynamics modeling was made with a view to receiving workpiece acceleration signals with a varied rotational speed of the spindle. “The diagram of modes” was plotted as a result of the acceleration signals analysis. The mode in which a self-excited vibration will not appear can be found in this diagram. The test experiments were carried out to mill the blade model with chosen parameters. Finally, the authors compared the experiment and modeling results to check the methods.

V. A. Kuts, S. M. Nikolaev, I. A. Kiselev
On Bending of Rod Under Strong Longitudinal Compression

In this paper, we consider typical processes of rod bending under strong longitudinal compression. The corresponding dynamic equation of bending is considered as a perturbation of the two-dimensional Laplace equation. It is established that, for these processes, expanding of domains of rapid increase of bending begins in small neighborhoods of singularity points of solutions of the limiting Laplace equation. The initial stages of these increases are described using the Hardy integral. Several typical examples of the development of buckling of a rod under the action of strong compression are simulated in the work.

A. A. Ershov, A. A. Ershova
Analysis of Forced Bending Vibrations of Straight Pipe with Flowing Fluid

The authors made a computational study of forced oscillations of a straight pipe with a flowing fluid under an external driving force using beam model. The phase shift of the oscillations of two points of the tube was obtained considering the noncentral application of the driving force and the asymmetry of the location of the sensors. The approach proposed was aimed at solving the problem of forced oscillations of a beam with a flowing fluid. It enables to use the beam modal shapes with a standing fluid found by the finite element method. The equation of transverse vibrations of a beam with a flowing fluid with an allowance for internal friction on the tube material was proposed. The allowance for friction on the tube material made it possible to solve the problem of forced resonance oscillations of a beam with a flowing fluid in a nonstationary formulation. The results obtained on the beam model were verified using a three-dimensional finite element model of a straight pipe with the flowing fluid. The results obtained can be used in prototyping Coriolis flowmeters.

P. A. Taranenko, D. V. Telegin, V. A. Romanov
Simulation of Flows in Bottom Field of an External Expansion Annular Nozzles

The scheme of flow in external expansion annular nozzle with short-cut center body is considered. The characteristic feature of the flow in such nozzle is the presence of a developed separated field behind the bottom of the shortened central body, the parameters of which are determined by the shock-wave interaction of gas flows flowing from the minimum cross section of the nozzle, representing the annular split, the plane of which has a significant slope to the longitudinal axis of the nozzle. The conditions of the open bottom field and closed bottom field in annular nozzles of the viewed type depending on the value of the environment pressure are allocated. The considered configuration of the annular nozzle featured a significant increase in pressure on the surface of the central body as a result of the presence of a shock-wave system that occurs immediately after the gas flows through the annular split. The shock-wave flow pattern is determined for annular nozzle for condition of closed bottom field.

A. L. Kartashev, M. A. Kartasheva
On the Economic Viability of Reusable Space-Rocket Systems Use to Deliver Payloads to Satellite Orbit

One of the important tasks of space exploration is the delivery of cargo for various purposes to low Earth orbits (further—SO: satellite orbit). Traditionally, such tasks were solved with the help of disposable carrier rockets and used to bring payloads (including manned spacecraft) into these orbits. The problems of economic viability evaluation to define the expediency of use of reusable space-rocket systems for the payload delivery to satellite orbit are considered. The examples of reusable space-rockets systems for delivering payloads to satellite orbit are given. The method of determining the economic efficiency of reusable space-rocket systems is considered. This method allows evaluating the advantages of each of reusable space-rockets systems under consideration and to determine the possibilities for their effective application. The results of the cost estimation per 1 kg payload delivery for various types of launchers including reusable space-rocket systems are given.

E. A. Kartasheva
Mechanics of Uniform Motion of a Rigid Body

This article analyzes the force parameters of the processes of solid body motion when external and internal forces act. On the basis of the analysis of the mechanics of the process of uniform motion of a rigid body, the authors found necessary conditions for uniform motion of it or its static equilibrium when balanced external forces act. A uniform motion of a rigid body under the action of balanced external forces of motion and resistance to motion is realized when these forces have independent sources of energy that interact with each other due to the displacement of a solid body. In this case, the energy source of the force of motion expends a certain amount of energy and the source of resistance force accumulates the same amount of mechanical energy by transferring the mechanical energy from the source of energy of the driving force to the source of the energy of the resistance force.

I. V. Dobrov
Development of Device for Evaluating the Performance of Rolling Bearings

In this paper, the problem of estimation of working capacity of rolling bearings is considered. To date, a wide application has been made of devices in which the rings of an adjustable bearing are connected to an electrical circuit in series with a voltage source and a measuring device that determines the parameters of the electric current through the bearing. Herewith, rolling friction parameters are not taken into account. The disadvantage of such devices is a low informative and limited application area. To eliminate these drawbacks, a device for diagnosing rolling bearings has been developed. The device operation consists in determining the rotational speed of the electric motor, at which the rolling elements of the elastohydrodynamic layer forming on the friction surfaces completely separate their surfaces while the current flowing through the surfaces of the rolling bodies is absent. When the motor speed is changed by means of the frequency converter of the motor supply voltage, at different values of the axial and radial loads being applied, as well as their joint action, the amplitude of the current flowing through the test bearing is recorded on the monitor in the form of a diagram using the converter R3 and the computer, on which the influence of friction parameters on the formation of an elastohydrodynamic layer between the surfaces of rolling bodies is determined. The presented developed device will allow increasing the informative value when evaluating the performance of rolling bearings.

V. G. Shram, A. V. Lysyannikov, N. N. Lysyannikova
Mathematical Model for Determining Depth of Deformation Penetration While Pipe Punching

This article speculates on the topic of inhomogeneity of crystal size in production of pipes with a diameter over 600 mm by means of punching and mechanical processing. It analyses literary data which allows to suggest that the reason for crystal inhomogeneity is inhomogeneity of deformation caused by voltage dissipation. There is a comparison of the punching process and mother pipe rolling on the stage of blooming where one can also observe voltage dissipation. It contains a conclusion stating similarity of these processes and suggests using the formula of Sun Rui Yu to evaluate the depth of deformation penetration on a piercing mill. There is an algorithm elaborated for usage of this formula requiring determination of a feed pitch. It should be noted that the given method suits only those mills where it is possible to ignore mother pipe twisting. The given method was used for calculating the depth of deformation penetration for one of the schedules. Possibilities and boundaries of method application are summarised.

D. V. Perevozchikov, V. N. Yeremin, L. V. Radionova

Friction, Wear and Lubrication in Machines

Frontmatter
Investigation of Kinetics of Wear in Friction Pair of Type “Undercuff Neck–Cuff Edge”

The interaction of friction surfaces for pairs of the type “undercuff neck–cuff edge” in the design of closed, radial, ball, single-row bearings with built-in contact seals, used as support for the belt-driven rollers on John Deere 864 balers, is described. On the basis of conducted research, it is established that the cause of destruction of the investigated bearings seals is a significant increase in temperature in the contact zone due to the appearance of contact stresses induced by the misalignment of bearing outer and inner rings. The kinetics of wear in a friction pair of the type “undercuff neck–cuff edge” was investigated. The dependence of the friction torque versus the temperature in the contact seal is presented. The physical model of wear in a friction pair of the type “undercuff neck–cuff edge” is described. The effect of the gap size on the lubricant leakage from the bearing cavity is investigated.

A. O. Gorlenko, S. P. Shetz
Qualitative Research of Combined Friction in Contact of Elastic Wheel with Solid Surface

This article describes the results of an experimental research of combined friction in the contact of an elastic wheel with a solid surface for the purpose of qualitatively determining the relative location of the areas with static friction and sliding friction relative to the linear velocity vector of the wheel. The experiment was carried out on a special installation with a glassy support surface, using video equipment to record the results. The conclusions are drawn about the qualitative arrangement of areas with static friction and sliding friction in the contact relative to the linear velocity vector of the wheel. The conducted research showed that, when modeling the rotation of a wheeled vehicle, the areas with the static friction are displaced aside, opposite to the direction of the lateral force, and when modeling the braking—in the direction opposite to the direction of speed of a sliding wheel. A further study of combined friction in the contact and the development of the methods for their investigation will correctly simulate the stability and controllability of the wheeled vehicle under various modes of its motion. Also, the results of the paper can be useful in developing new algorithms for the functioning of drive control systems of wheeled vehicles.

E. V. Balakina, D. S. Sarbaev
Modeling of Various Types of Surface Wear

The applied criteria for critical (limiting) levels of wear for various types of wear are listed. Based on the discretization of the volume of wearing parts and the time axis, a method is developed for calculating the following wear types: erosion, cavitation, abrasive wear at the boundary friction regime, and others. In the proposed methodology, it is possible to simulate the simultaneous occurrence of several types of wear both at different parts of the surface of the object and on the similar ones. It is possible to take into account the mutual influence of various types of wear. The dual nature of wear is taken into account: on the one hand, the wear values are dispersed even for the same levels of influencing parameters, on the other hand, providing consistent wear values of the surfaces in accordance with the kinematic schemes of their loading in conjugation. Various variants of the joint wear of surface sections in various interfaces are taken into account. For different types of wear, different calculation models can be used, collected in the appropriate model libraries. As an example of the tribo node, sliding bearings with a Babbitt layer are chosen. Parameters of the Babbitt wear models based on tin were experimentally obtained by the authors or taken from scientific and technical literature. Several series of calculations of tribo nodes with Babbitt layers have been performed and the calculation method working capacity has been demonstrated.

M. V. Zernin, A. G. Yashutin
Magnetic Nanodisperse Oils Based on Organosilicone Fluids: Lubricant Properties of Oils with Different Additives

The paper describes the results of studies aimed at creating and studying magnetic lubricating oils that contain organosilicone fluids as a dispersion medium and steadily operate in the frictional knee boundary friction mode. The paper also investigates lubricating properties of magnetic oils based on oligodiethylsiloxane and oligomethyl(chlorophenyl)siloxane under various friction conditions and shows their specific features. It analyzes the influence of various additives and fillers on tribotechnical characteristics of magnetic oils. It also defines a different mechanism of additives effects on frictional contact properties and proposes its description. It is established that a magnetic oil service life is comparable with one of the transmission oils, for example, TM-5-18; it is also two or three orders greater than the one of the plastic lubricant OKB-122-7. According to the results of magnetic oil tests, there were determined some compositions that are the most promising for practical use in tribounits. Finally, the paper provides recommendations on the practical application of optimal compositions of magnetic lubricating oils in traditional and perspective tribounits with various operational parameters.

A. N. Bolotov, V. V. Novikov, O. O. Novikova
Four-Ball Machine Friction Unit Geometrical Parameters

Standard studies of the lubricants tribological properties are carried out on a four-ball friction machine. The friction unit of such machine is the same diameter contacting steel ball pyramid. To provide normal operation of this unit, it is necessary to ensure the upper pyramid ball stable sliding over the three lower fixed ball bearings. Other friction unit balls movements and displacements are unacceptable. Creating a calculation model friction unit makes it possible to determine such conditions. These model static equilibrium equations are the basis of the friction unit balls. Recording equilibrium equations with subsequent solution allows to perform analysis of the friction unit parts geometrical parameters effect onto stable operating conditions and to determine the optimum values of these parameters. The results can be used to create new laboratory facilities for the of the lubricants tribological properties study and to improve this four-ball machine.

A. M. Antimonov, N. B. Pushkareva, E. G. Reshetnikov
Cylindrical Shell Edges Bending Process Technological Features

Mills with three rolls for bending sheets are widely used in the manufacture of large diameter welded pipes, tanks, and other long cylindrical products. Flat edges remain on the product after bending. The edges bending to the curvature product radius can be done with longitudinal rolling on special machines. For these machines, designing a methodology for calculating process power parameters must exist. The proposed technique is based on the bending model in dies with taking into account the influence of the noncontact deformation zone during sheet rolling. As a result, simple analytical dependencies for the vertical force engineering calculation, the rolling moment, and the noncontact deformation zone were obtained. The possibility verification of their application showed good convergence of the calculated and experimental data.

A. M. Antimonov, N. B. Pushkareva, E. G. Reshetnikov
Magnetic Nanodispersed Lubricating Oils Based on Organosilicon Fluids: Basics of the Technology

The results of studying tribotechnical and physicochemical properties of various liquids have proved applicability of a dispersion medium, which is based on organosilicon liquids, for producing new-generation magnetic lubricating oils. The paper gives recommendations for choosing a dispersed magnetic phase. It analyzes the accumulated experience on choosing the materials to stabilize colloidal particles. It also shows an original approach to selecting surfactants that are intended for stabilization of a magnetic oil colloidal structure, taking into account their dielectric properties and the effect on friction. There are data on the preliminary selection of additives and fillers for a magnetic oil, which are characterized by various mechanisms for reducing friction and wear of lubricated surfaces. The paper shows the efficacy of additives under various operating conditions of a friction unit with a magnetic oil. It describes technological features of the synthesis of lubricating oils based on polyethylsiloxane PES-5 and chlorophenylsiloxane KhS-2-1VV containing nanosized magnetite. The authors have obtained promising magnetic lubricating oils with good lubricating properties: low volatility and a wide temperature operating range.

A. N. Bolotov, V. V. Novikov, O. O. Novikova
Measurement Technique for Temperature of Friction Lining of Brake Roller for Pallet Flow Rack

One of the types of high-density storage systems is a pallet flow rack. A brake roller is one of the safety elements of pallet flow racks, which is necessary to limit the speed of transportation of the pallet. The design of the most common construction of such brake roller is closed and maintenance-free. Therefore, it is important to increase the service life of the brake roller; one of the determining factors of which is the temperature of the friction lining. This article presents a measurement technique for determining the temperature of the friction lining of the centrifugal brake of the roller. For this purpose, a stand-alone measuring unit has been designed to transmit the readings of a K-type thermocouple mounted in one of the linings via a radio signal. An experiment was performed to determine the temperature conditions of the friction lining for a sample of the brake insert for a different number of braking per hour. According to the obtained data, the temperature of the friction lining during the braking process does not exceed 28–33 °C. Thus, having experimental data on the temperature mode of the operation of the friction lining, it is possible, based on known tribological characteristics of material of lining, to evaluate the operability and operating life of the friction pair of the brake roller.

E. Safronov, A. Nosko
Assessing the Impact Strength of Blade Edges of Forestry Machinery Operating Components

This paper discusses how to assess the impact strength of the blade edges of forestry machinery operating components. The impact of the material under processing is the main factor contributing to the destruction of cutting edges. In soil-cutting, multiple percussive impacts on the blade edge result in the accumulation of volumetric damage, which makes the soil-cutting components blunt and less efficient. We have used an impact tester to carry out impact strength tests of blade edges by means of which we obtained data on how the hole depth would alter depending on the number of strokes in a semilog coordinate system; the depth alteration conformed to the linear law, and the depth would no longer alter past 500 strokes. The blade edge was destroyed mainly due to the plastic displacement of metal toward the base layer. The accuracy of this method for determining the strength parameters of blade edges was assessed by means of a set of statistical data on the depth of 30 holes on steel blades with a miter angle of 40° that had been heat-strengthened to 5558-HRCЭ.

V. A. Markov, V. A. Sokolova, V. I. Kretinin
Wearing of MR Wire Vibration Insulation Material Under Random Load

Vibration insulators and elastic-damping supports made of MR (metal rubber) wire material are widely used. The wearing of this material under random load is researched. The material is considered as anisotropic continuous media. A middle stress in the material is taken as a load parameter. Changing of resonance frequency and vibration transfer coefficient at resonance during lifetime is researched as dependencies on middle stress and density of material. The equations describing these dependencies are obtained. Three types of wearing are described as dependencies on load and MR material parameters. The wire microphotographies after wearing are obtained. The mass lost during wearing as the dependency on stress and density of material is researched.

A. M. Ulanov, S. A. Bezborodov
Experimental Evaluation of Influence of Tool Wear on Quality of Turning

This article is devoted to the evaluation of the effect of tool wear on the quality of the machined surface in turning on the metal cutting machines. The modern level of measuring equipment allows to obtain a qualitative assessment of the roughness indices of the treated surface. For the experiment, the Triebworx T4HD profilometer-contourograph and the optical three-dimensional microscope Contour ELITE were used as measuring instruments. The equipment was provided by Optec. The results of the experiment made it possible to obtain a qualitative tool wear characteristic on the back face and to associate it with a characteristic that reflects the changes in the surface quality of a part in time. As the main conclusion formed by the results of processing the data obtained in the experiment, it is argued that the quality of the treated surface depends little on the degree of tool wear until the moment of approaching the catastrophic level of wear. With the approach of wear to the catastrophic point and its further increase, the quality of the treated surface sharply deteriorates. The dependencies obtained in the work as a whole coincide with the realistic approach to the evaluation of the dynamics of the processes taking place in metal cutting machines. According to this approach, during the cutting process, several evolutionary sections are observed: the tool run-in and stabilization area, both of the dynamics of the control system and the quality of the parts produced, and the sharp increase in the tool wear (catastrophic wear) in which the dynamics of the system becomes unstable, and the quality of the treated surface sharply deteriorates.

V. P. Lapshin, T. S. Babenko, D. V. Moiseev
Development of Measures to Prevent Surging Turbochargers of Cars

The priority direction of the development of mechanical engineering is the increase in the energy saturation of the automobile and tractor fleet. One of the most effective ways of boosting modern engines is turbocharging and the use of turbochargers (TCR). However, along with a positive effect—boosting and increasing the power in the range of 5–50%, there is a significant drawback—a decrease in the engine reliability. The main reasons for this are: high stochastic load conditions, which is 10–150%, depending on the type of the work performed. The use of the hydraulic accumulator providing additional lubrication of the TCR rotor bearings predetermines an increase in the rotor run-out time by a factor of 1.5–2.5, and, correspondingly, an improvement in the design parameters of the accumulator. When connecting the brake device, with a simultaneous integrated application of the accumulator, the duration of the run-out of the TCR rotor is reduced by 30–40%. In this case, providing the accumulator with a standard accumulator lubrication of the rotor bearings enables to reduce the volume of the accumulator to 2.0–2.2 L and its dimensions in 1.2–1.5 times. But at the same time, there are surging phenomena of moving with a high-speed air flow. To prevent surging, it is necessary to study the spectrum of eigenfrequencies and the shape of the oscillations of a brake device damper. For this purpose, a classical experimental vibration setup was used and the first five resonance frequencies were determined.

A. V. Gritsenko, V. D. Shepelev, A. V. Samartseva
Semigraphical Method of Motor Oils Thermal-Oxidative Stability Index Control

At present, it is impossible to establish the effect of temperature on the aging processes of motor oils, base oil base, and additives without experimental studies. In this article, the research methodology and experimental results of thermooxidation stability indicators including the optical density, volatility and thermal oxidation coefficient of Texaco Extra 10W-40 SL/CF motor oil are presented. The thermal and oxidation stability of the oil under investigation was determined from the change in optical density and evaporation. An analytical relationship between the thermooxidation stability and the test temperature was established, on the basis of which a graphoanalytical model for predicting these parameters at other test temperatures was proposed. The use of this method of research is aimed at determining such performance indicators for the quality of motor oils as the temperature of the beginning of the processes of transformation in oil and the critical temperature of these processes, which determine the temperature range of its efficiency. The proposed performance indicators will allow one to compare lubricants and identify them for compliance with the groups of operational properties.

B. I. Kowalsky, V. G. Shram, A. V. Lysyannikov
Comparison Method of Engine Oils on Thermooxidizing Stability Indicators

The results of a research of thermooxidizing stability of synthetic engine oil Mobis 5W-30 SL/CF with application of the graphic-analytical model expanding information about durability temperature range are presented. The research method and base of debugging tools and test means are presented in the first part of paper. The oil sample was thermostated in the specified temperature range (from 160 °C to 190 °C). Evaporability, optical density and thermooxidizing stability coefficient were determined during the research. Then the equations of the graphoanalytical model were computed and the rest values of the thermooxidizing stability coefficient were calculated without testing. The dependences of thermooxidizing stability coefficient on time testing at various temperatures, decimal logarithm of first passage time by thermooxidizing stability coefficient the set values, potential resource on testing temperature, thermooxidizing stability coefficient on testing temperature and first passage time by thermooxidizing stability coefficient the set value on testing temperature of synthetic engine oil Mobis 5W-30 SL/CF are presented by authors in the part “The results of research”. Regression equations, which describe the obtained dependences, are established. New indicators of thermooxidizing stability are offered. Regression equations characterize the temperature of temperature reforming beginning in the oil sample and the critical temperature at which there come the abnormal phenomena of processes of oxidation and evaporation.

A. N. Sokolnikov, O. N. Petrov, V. I. Vereshchagin
Electrometric Control Method for Processes Proceeding at Boundary Sliding Friction

The results of research of the processes proceeding on frictional contact at boundary friction at a transmission through it a direct current are presented. The research method provided determination of optical and antiwear properties of oils. The three-ball friction machine with a “ball-cylinder” scheme is used for the research of antiwear properties. During the testing, three fixed balls contact with rotating cylinder along individual friction paths. Through the friction couple, an electric current of a certain magnitude and polarity is passed, the change of which is recorded as a diagram on the computer monitor. The antiwear properties were evaluated by the formation time of the protective boundary layer and the arithmetic average value of the diameter of the wear spot on three balls. The optical properties of the oils were estimated from the absorption coefficient of the light stream. The influence of the current polarity on the antiwear properties of oils was investigated for commercial and brown oils of different base basics in the conditions of a change of the magnitude and current polarity passed through the contact of the balls and the cylinder during friction. In addition, the load on the balls changed and the influence of the operating parameters on the formation time of the frictional contact area was estimated.

O. N. Petrov, A. N. Sokolnikov, D. V. Agrovichenko
Radial Friction Bearings Conditioned by Melt

The paper presents a technique and an accurate implementation of a self-similar solution of the problem of calculating the hydrodynamic endless radial friction bearing coated by low-melting-point metal of bearing bush operating at a viscoelastic lubricant with the account of the dependence of viscosity of the lubricant and the shear modulus on temperature. Based on the equation of motion of the liquid lubricating material having viscoelastic properties (Maxwell liquid) for the case of a “thin layer”, with the dependence of the viscosity of the lubricant and the shear modulus on the temperature, the continuity equation and the energy dissipation rate for determining the function of formula $$ \Phi \left( {\theta } \right) $$ , conditioned by the melt surface of the bearing bush coated by low-melting-point metal, the asymptotic solution for the zero and first approximation in powers of the small parameter K conditioned by the melt are found. As a result of problem solving, the velocity field and pressure in the lubricating layer and the molten layer are determined, as well as the value of the function $$ \Phi _{ 1} \left( {\theta } \right) $$ conditioned by the melt surface of the bearing bush coated by low-melting-point metal. The numerical analysis of the obtained analytical expressions for the load-bearing capacity and friction force with simultaneous consideration of important factors such as the viscosity of liquid viscoelastic lubricant, shear modulus, Deborah number, the parameter characterizing the dependence of viscosity on the lubricant, and shear modulus on temperature, allowed one to refine the tribotechnical design models in the following order: load-bearing capacity by 22%, frictional force by 27%.

E. O. Lagunova, M. A. Mukutadze
Application of Bio-oil in Hydraulic Systems

One of the main development trends of modern technologies is a wider application of environmentally friendly and renewable products, such as bio-oil for hydraulic systems. However, pure bio-oil does not always satisfy the high requirements of modern hydraulic systems. One of the ways of reducing a flow rate of hydraulic oils is the use of vegeto-mineral mixtures of oils in hydraulic systems. Camelina oil (Camelina sativa) is one of the cost-effective products. In order to verify the possibility of using a Camelina oil mixture as a substitute of mineral hydraulic oil in hydraulic systems, a benchmarking laboratory analysis of mixtures with a different percentage composition was performed followed by an evaluation of their viscosity/temperature and anti-wear properties. On the basis of the results obtained during the studies, it was found that Camelina oil mixtures with percentage ratios of 90% of VMGZ hydraulic oil (equivalent of Shell Tellus 15, Mobil DTE 11M, TEBOIL Hydraulic Oil 15, Castrol Hyspin AWS 15) and 10% of Camelina oil and 75% of VMGZ hydraulic oil, and 25% of Camelina oil correspond to the commercial mineral oil in terms of their density, viscosity/temperature and anti-wear properties and can be used as its substitute in hydraulic systems of automobiles and tractors.

A. S. Khusainov, A. A. Glushchenko, F. F. Zartdinova
On Support of Optimization Criterion of Recovery Process of Motor Oils

One of the ways of efficient use of waste motor oils is their recovery, i.e., purification and recovery of performance properties for further reuse. It not only saves petroleum products but also reduces their negative impact on the environment. The performed analysis showed that there is no optimal procedure for evaluation of the selectable waste oil recovery technologies at the present time. The experience of optimization of energotechnological systems has shown great value of thermodynamic methods of analysis which allow finding optimal schemes and parameters of the recovery process on the basis of thermodynamic relations using simpler but at the same time more precise methods. Searching for the best options of energotechnological schemes of recovery units on the basis of the thermodynamic effectiveness indexes allows, in most cases, obtaining necessary information about its energy efficiency. At the same time, the most advanced basis for performing such analysis and optimization is an exergy concept resulting from the second law of thermodynamics The exergy analysis method allows evaluating the degree of utilization of energy, its losses, as well as obtaining energy-loss distribution over separate devices of the system and finding the least effective ones. The suggested procedure of thermodynamic optimization allows reliably selecting such a method for the recovery of waste oils from many suggested ones which provides the maximum saving of energy resources, and the exergy analysis allows objectively evaluating the practicability of the recovery of waste motor oils.

A. S. Khusainov, A. A. Glushchenko
Determining the Parameters Effecting the Work of the Lubricants Supplying System at Wide-Strip Hot Rolling

The article dwells upon the assessment of operation efficiency of lubricants supplying system through the whole finishing group at continuous broadband hot rolling mill “2000” Jointstock Venture Company “Magnitogorsk Iron and Steel Works”. The lubricants influence on the main hot rolling technology parameters is analyzed. As a result of the research, there was constructed a regression model to define the “lubricants presence” coefficients in the roll contact. Using lubricants while rolling process makes it possible to reduce external friction forces on the contact surface. From rolling production theory and practice, there is widely known that all kinematic and energy power parameters in one way or another depend on external friction force. While decreasing pressure on the rolls, energy expenses also get reduced. Using lubricants also allows to produce high strength steel brands, capable of withstanding high unit loads, and harsh work conditions. There were used statistics methods to evaluate lubricants impact on rolling parameters changes with the goal of subsequent withdrawal regression function for the stands № 10–13. Regression equations were obtained with the use of “Statistica” software, they allow to define the moments of the main driver’s shaft while using lubricants. There were calculated numerical meanings of the lubricants impact coefficients on the energy power parameters changes depending on the rolled out metal group.

Roman R. Dema, Ruslan N. Amirov, Olga B. Kalugina
Tribological Research of Biodegradable Lubricants for Friction Units of Machines and Mechanisms: Current State of Research

At present, tribological studies are dominated by empirical and statistical approaches. Regardless of the availability of some standardized methodologies and devices, unique designs, taking into account the variety of conditions affecting friction and wear mechanisms, are being developed. This circumstance makes it difficult to analyze and compare the experimental results of individual authors. The complexity of creating a unified approach in tribology is due to the mutual influence, change and distribution of contact structures and parameters in the friction process, as well as the difficulty of measuring them in the friction process itself. The objectives of this study are: to identify the main mechanisms and patterns of friction and wear of contact systems lubricated with vegetable oils and vegetable-mineral compositions, with new synthesized antifriction and anti-slip additives, and to identify and scientifically establish opportunities for triggering self-organizing processes in contact that have an effect low friction and wear, and especially friction without wear. This article presents an initial overview of the current state of research in the field of the use of biodegradable lubricants for friction units of machines and mechanisms. It was concluded that the task of developing a lubricant with simultaneously high tribological characteristics, resistance to operational influences, extremely low toxicity, and high biodegradability remains urgent to this day.

E. Zadorozhnaya, I. Levanov, M. Kandeva
Contact of Rigid Rough Surface Through Polymer Coating Layer

The article is devoted to the analysis of engineering approaches to determining the value of the indentation of a spherical and rough surface into a polymer layer. It is pointed out that in most cases, the classical solutions of contact problems for bodies with varying mechanical characteristics do not allow the applied results to be applied for practical purposes to provide the specified conditions for friction, wear, and tightness. It is shown that engineering methods of solving contact problems on the basis of simplifying hypotheses are more practical, for example, the representation of a layered body as a construction with special mechanical properties that depend on the mechanical properties of base and coating materials and the thickness of the coating. The analysis of the use of the proposed engineering solutions in calculating the value of the indentation of the sphere showed the advantages of the method based on the rigid model of a layered body. In this case, the effective modulus of elasticity and the Poisson’s ratio are determined for any values of the coating thickness for an axisymmetric loading of a layered half-space. To determine the value of the indentation of a rough surface into the polymer layer, a discrete model of a rough surface is used. When contacting a rough surface through a polymer layer, it was taken into account that each asperity corresponds to a certain modulus of elasticity which is determined by the level of the peak and the value of approach.

P. Ogar, A. Kozhevnikov, V. Elsukov
Relative Contact Area by Indentation and Flattening of Rough Surfaces Spherical Asperities

The paper indicates that the application of roughness models and the theories of contacting rough surfaces developed by Greenwood–Williamson and N. B. Demkin for solving the problems of hermetology leads to significant errors. This is explained by much greater contact pressures than assumed for the tribology problems, describing only the initial part of the reference surface curve and the lack of allowance for the plastic extrusion of the material. A brief review of methods for describing the introduction of a sphere into an elastoplastic reinforced half-space is given. The properties of the elastoplastic reinforced material are described by the power law of Hollomon. To describe the indentation and flattening of single spherical asperity, the results of finite element modeling are used. The cases of contacting a rigid rough surface with an elastoplastic half-space and a rigid smooth surface with a rough surface are considered. To determine the relative contact area, the discrete roughness model is used in the form of a set of spherical segments distributed along the height in accordance with the curve of the reference surface.

P. Ogar, D. Gorokhov, E. Ugryumova
Influence of Friction Geo-modifiers on HTHS Viscosity of Motor Oils

Motor oil of the internal combustion engine is a means to deliver particles of friction geo-modifiers to the friction surfaces. In this case, the influence of friction geo-modifiers such an important parameter as engine oil HTHS viscosity is of practical interest. The purpose of this article is to determine the HTHS viscosity multigrade engine oils of SAE class 5W-40 with different concentrations of friction geo-modifiers on the basis of pure serpentine. The tapered bearing simulator TBS 2100E TANNAS was used to measure the viscosity of oils at shear rates 106 s−1. A lubricating composition was prepared using two samples of multigrade engine oils viscosity grade SAE 5W-40. The mass concentration of the friction geo-modifiers was 0.1, 0.3, and 0.5% in each sample. The friction geo-modifiers lead to insignificant decrease in HTHS viscosity multigrade engine oil of viscosity grade SAE 5W-40. The viscosity decreased on 3.5–6.5% for the analyzed samples of motor oils. Therefore, the working conditions of the bearings of the crankshaft are changed insignificantly at the introduction of the friction geo-modifiers in motor oil.

I. Levanov, E. Zadorozhnaya, D. Vichnyakov
Application of Method of Molecular Dynamics (MMD) for Modeling the Process of Dislocation of Hardening of Surface Zone

This article analyzes the modeling process of hardening using a molecular dynamics method with the example of formation and subsequent cleavage of edge dislocations at the superficial zone of carbonitriding heat-resistant steel during sliding friction using industrial grease. Previously obtained experimental data of the surface area of friction reflect the processes of structure formation in a continual approximation and thus, allow to identify its main characteristics. In particular, setting higher diffusion coefficients and lowering temperature ranges during phase transitions reveal that the cause of the anomalous behavior of the diffusion processes is thermal shock leading to the occurrence of highly pressurized area of “compression–expansion” in the surface layer of the hardened metal. However, using the methods of continual approximation, a high speed of diffusion processes does not allow us to establish a number of features of these processes, which affect both the formation of secondary structures and their tribotechnical properties. This is a quantitative assessment of the process of prediffusion excitation of atoms in the form of: appearance of vacancy clusters, intrinsic interstitial clusters, and dislocation loops, i.e., about the damage to the surface layer at this stage.

P. I. Malenko, K. J. Relmasira, A. Yu. Leonov
Influence of Location of Lubrication Sources on Hydromechanical Characteristics of Diesel Crankshaft Bearings

The technique for determining the movable (holes in the crank bearing) and fixed (grooves on the surface of the pad) lubricant sources for lubricant supply to the heavy-loaded friction type bearing is considered. To determine the field of hydrodynamic pressures in the bearing lubrication layer, two modifications are taken into consideration: the modification of the algorithm for integrating the modified Elrod equation for the degree of the gap feeling. Further studies showed that developed modifications were proved to be quite effective in calculating the characteristics of the lubricating layer for both statically and dynamically loaded bearings. However, for the first modification, numerical oscillations of the unknown function at the boundary of the reduction of the lubricating layer were noticed. The second modification, for which the finite difference algorithm was used, is characterized by the simplicity of implementation and the stability of the iterative procedure. The example of connecting rod bearings of the crankshaft of the combustion engine is used to consider the influence of the location of the lubrication sources on the hydromechanical characteristics of complex loaded friction type bearings. Original schemes of location of partial and complete oil distribution grooves for lubricant supply for connecting rod bearings are proposed. It is shown that an additional method for improving hydromechanical characteristics is the selection of engine oil with improved viscosity–temperature characteristics.

Y. Rozhdestvensky, K. Gavrilov, A. Doikin
Numerical Model of Mechanical Interaction of Rough Surfaces of Journal Bearings of Piston Engine

The reliability of many machines and mechanisms is mainly determined by the reliability of friction pairs (in particular, journal bearings). So the journal bearings in the piston engine are mostly operated in the hydrodynamic lubrication regime and, at high loading levels, in the transient and mixed lubrication regimes. The latter is important for the determination of the service life of the tribosystem as a whole. For this aim, in this paper, we describe, develop, and apply an approach proposed earlier to build models of the interaction of rough surfaces for one of the tasks of simulation of tribological systems of the piston engine. Previously suggested models can estimate the area of contact, the friction force, coefficient of friction, wear, etc. However, this approach ignores the surfaces change and, consequently, contact and friction characteristics over the time. We described the general approach to build a model of interaction between rough surfaces, leading to the analysis of the Markov process. This method we applied for friction process and for the fatigue failure mode in which the surface element is destroyed after repeated contacts, the order of many millions. Given the initial data and the method of calculating the trajectory of movable elements on the lubricating layer taking into account rheological characteristics of lubricants, we determined the tribological parameters defining the resource of crankshaft bearings and the “piston–cylinder liner” tribosystem of the high forced piston engine.

K. Gavrilov, A. Doikin, M. Izzatulloev, Y. Goritskiy
Fracture of TiC/a-C(:H) Coatings in Friction Contact

Carbon-based coatings have excellent mechanical, electrical, and chemical properties. The tribological performance of these compounds is difficult to predict as it depends on a nonlinear interaction of different parameters as testing conditions, surrounding atmosphere, nature of the counterfaces, and film properties, so that a careful study of the structure–properties correlation is needed. This study is focused on the difference in tribological properties and fracture of the coatings, which are designed using two different types of a magnetron sputtering technology: high power impulse (HiPIMS) (pulsed) and direct current (DC) (non-pulsed). The work includes friction tests, calculation of internal stresses and microscopic study of the sample surfaces before and after friction, and analysis of chemical composition of surface layers and wear particles. The difference in friction and wear mechanisms depending on the applied technique is analyzed. The results showed that friction coefficient against 100Cr6 balls and internal stresses are greater for DC coatings, although they have a better resistance to brittle crack formation.

E. Torskaya, A. Mezrin, Juan Carlos Sánchez-López
Study of TiC/a-C(:H) Coatings Before and After Friction by Nanoindentation

This study is focused on the analysis of the surface geometry and elastic properties of carbon-based coatings, which are deposited using a high power impulse (HiPIMS) (pulsed) and direct current (DC) (non-pulsed) magnetron sputtering. The work includes friction tests, microscopic (SEM and AFM) study of the samples surfaces, their roughness before and after friction, indentation of initial and worn surfaces, and estimation of Young’s modulus of coatings before and after friction using analytical–numerical modeling. The analysis of nano-roughness by AFM shows that worn tracks are very smooth even for an initially rough surface. DC coatings have similar elastic properties before and after friction. HiPIMS coatings become more compliant after friction, which is probably due to the formation of a thin compliant film at the surface of the coatings.

Elena V. Torskaya, Tamara I. Muravyeva, Juan Carlos Sánchez-López
Research Results of Influence of Synthetical Additive on Temperature Parameters of Moto Oils

The results of the study of the temperature parameters of the partially synthetic motor oil RosneftMaximum 10 W-40 SL/CF are presented, and the influence of the synthetic additive in the amount of 20% on the temperature parameters of the motor oil is determined. The device for oil thermostating of the photometric appliance and electronic scales were used for this research. The research technique of motor oils in two stages using devices for thermostating of the motor oils, photometric appliance and electronic scales is described. At the first stage, semi-synthetic motor oil RosneftMaximum 10 W-40 SL/CF was experienced; at the second one, a synthetical additive in the amount of 20% was added. The dependences of optical density, potential resource, volatility with time and testing temperature of synthetic motor oil are constructed. Time to reach optical density, volatility and thermo-oxidative stability factor was determined on these dependencies. Further, with the help of these findings, a dependence of time to reach set values of optical density, volatility and thermal-oxidative stability factor with temperature is constructed, using them the temperatures of the onset of oxidation, volatility and change thermal-oxidative stability factor, and the critical temperatures of motor oil and of motor oil with a synthetical additive in the amount of 20% are determined.

B. I. Kowalski, E. G. Kravcova, N. N. Lysyannikova
Effect of Adhesion Properties of Frost-Resistant Rubbers on Sliding Friction

Results of experimental study of rubber friction in dry sliding contact with a steel smooth counterbody are presented. Two types of frost-resistant elastomers are studied, which are based on propylenoxide rubber with high and low adhesion controlled by addition of carbon black. Adhesion properties of the rubbers are determined from experimental approach–separation curves obtained by the atomic force microscope (AFM). Roughness parameters of the rubber and counterbody are also measured by AFM. The obtained values of the adhesion properties and roughness parameters are used to calculate the coefficient of friction based on the model of a viscoelastic solid in sliding contact with a rigid indenter having regular surface roughness. The results of calculations are in good agreement with the experimental dependence of the coefficient of friction on the nominal pressure (ranging from 0.1 to 0.3 MPa) and sliding velocity (ranging from 1 to 100 mm/s) obtained at the room temperature.

A. V. Morozov, Yu. Yu. Makhovskaya
Control Method of Thermo-oxidative Stability Factors of Synthetic Motor Oil

This article presents the results of the research on the effect of temperature on a number of thermo-oxidative stability factors, including optical density, volatility, thermo-oxidative stability index and potential resource. The method of researching lubricating oils for thermal-oxidative stability is described; it includes the application of testing devices and control, such as a device for thermostating the oils, photometer for direct electrophoretic oxidized oils and electronic scales. The authors investigate the dependences of optical density, potential resource, volatility and thermo-oxidative stability factors on the time and testing temperature of synthetic motor oil, on the basis of which new factors of thermo-oxidative stability were proposed including the temperatures of the onset of oxidation, volatility and temperature transformations in oil, and the critical temperatures of these processes. This article proposes a grapho-analytical model for the definition of thermo-oxidative stability factors at all temperatures without the research based on oil testing under two temperatures, which makes it possible to reduce the labour inputs of the research by more than two times. The proposed control method of thermo-oxidative stability factors allows the authors to expand the information on the quality of lubricants by determining the onset temperatures of oxidation, evaporation and temperature conversions in oil, as well as critical temperatures of these processes. It also allows improving the classification system by the groups of operational properties.

N. N. Lysyannikova, E. G. Kravcova, M. A. Kovaleva
Ways of Increasing Wear Resistance and Damping Properties of Radial Bearings with Forced Lubricant Supply

The paper considers radial friction bearings of finite length, the fixed hub of which consists of a supporting part, a porous layer, and a liquid material. The existing methods of design calculations of such bearings are very approximate, since they do not take into account the nonstationary operating conditions of the shaft and the influence of the method of supplying the lubricant. The influence of these parameters on the stable operation of the triboconjugation under consideration is shown. In addition, as a result of the studies, the effect of multifunctional additives for lubricants in the form of nanoscale particles was established by studying the phase diagrams of systems of ceramic materials–oxides and condensed phosphates. This approach makes it possible to actively control the coefficient of friction by changing the state of surface films with boundary friction.

I. V. Kolesnikov, A. M. Mukutadze, V. V. Avilov
Development of Bearing Beam and Seal System for Main Pumps

In this article, we consider the possibility of using an integrated bearing beam and seal system in the place of classic separate bearing assemblies and mechanical seals for main pumps. The classification of possible states of main pumps is given taking into account the most characteristic types of incidents, failures, and accidents. As a result of the analysis (which was realized in this article), it was established that the most vulnerable components to failure are the bearing assemblies and mechanical seals, the specific number of failures of which is about 50% of the total number of main pumps failures. The main directions of the use of an integrated bearing beam and sealing system in the form of bearing and seal block (BSB) are indicated, the practical and scientific novelty of which consists in replacing the classical power unit of the pump equipped with rolling bearings on the bearing unit consisting of two single mechanical seals and a pair of plain bearings (radial and axis). This modernization allows increasing the life of main pump equipment, as well as its inter-repair interval. At the same time, it is ensured not only an increase in the reliability of the abovementioned bearing beam and seal system of the main pump but also an improvement in the quantitative indicators of reliability of the main pump remaining elements, in connection with the reduction of the overall vibrational and temperature background.

N. Berezhansky, A. Zaplatyn, R. Karymov
On Proof of the Generalized Lagrange Variational Principle

The proof of the generalized Lagrange variational principle for the case when the velocity field is a vortex of some auxiliary vector field is given in the present paper. The proof is obtained for Newtonian fluids. It is demonstrated that the generalized Lagrange functional takes a minimum value on a real field. The generalized Lagrange variational principle extends the class of solving problems to quasistationary ones and can be applied to solve problems in the hydrodynamic lubrication theory. To verify the theoretical results, a numerical solution of the variational problem of fluid flow in a thin layer between rigid parallel plates is performed. The numerical results match with the analytical results with a high accuracy.

A. V. Kornaev
New Method of Tribological Testing Lubricants and Antifrictional Additives

A new method of an experimental estimation of antifrictional properties of lubricants and corresponding additives is described. Unlike known methods, the offered one allows to carry out a testing during very short time which is not exceeding 60 s. Mainly, the method is oriented at the comparative test detecting an object leader among the other ones. The method is based on the known tribometrical principle consisting of removal of a rigid constraint of one of the bodies of frictional pair and its replacement by an elastic or solid measuring element sensitive to a frictional force. Frictional force, friction ratio, friction power, temperature and heat caused by a friction have been measured as tribological parameters. The method was put into practice by means of upgrading the well-known Timken extreme load friction test machine. Testing and processing received results are completely automated. Some results of the application of the method and corresponding equipment for tribological testing known motor oils are presented. The tests have shown high reliability and sensitivity of measurements within the scope of the method consisting in the possibility to estimate rapidly small changes of frictional parameters and to provide repeatability of results.

S. V. Putintsev, S. P. Chirsky, S. S. Pilatskaya
Friction and Vibration in Journal Bearings Operating with Nanofluids: Experimental Results

The article considers the influence of nanoadditives on the performance characteristics of radial slide bearings. The samples of lubricants were prepared on the basis of mineral oil with additives of fullerene soot and a mixture of fullerenes with a total mass fraction of not more than 0.01%. In the run-out mode, data were obtained on the rotational speed and vibro-displacement of the rotor, vibration acceleration of the bearing housing. Based on the results of the experimental data processing, Stribeck curves and trajectories and amplitude–frequency characteristics of the oscillations are constructed. The results showed a decrease in friction in bearing supports when using oils with additives. At the same time, the effect on the rotor vibration level was insignificant. The best results were shown by the addition of fullerene soot.

A. S. Fetisov, A. V. Kornaev, N. V. Tokmakov
Optimization of Piston Compressor Geometric Size Using the Genetic Algorithm Method

The study of strained-deformed state of piston compressor and a compressor-cylinder system is conducted. For that, the case of optimization of piston compressor geometric size is considered (the search of optimal configuration of piston contact zone) with the use of the genetic algorithm method, allowing to evenly spread the friction forces across the outer surface of the compressor, that occurs during the mechanism use. The methodology of the study of piston compressors in deformed strained state is proposed with adding strain function into geometric and physical equations of the classic linear elasticity theory. The comparison of the results has shown that the change approximation of elasticity module from the thickness of modified layer is the same as the experimental values. The use of target function in the form of weighed solution combination allows determining optimum compressor configuration for the most even spread of contact strains in the process of work and erasing the material.

O. V. Dushko, G. V. Voronkova, S. S. Rekunov
Development of Method and Instruments to Identify Efficiency of Tracked Vehicles

This article proposes a new method and instruments to determine the efficiency of a tracked vehicle. The developed method allows determining the torque on the tracks without the use of expensive equipment and strain gauges in the dynamic modes of operation. It allows controlling the instantaneous fuel consumption and calculating the efficiency of the vehicle on various road surfaces. One of the functions of the developed instruments is to alert the driver about the inefficiency of energy use and to adjust acceleration. The proposed method and instruments do not require any modifications in the design of a track, and they allow increasing their efficiency by selecting the optimal driving regime depending on the road surface.

K. E. Kozlov, V. N. Belogusev, A. V. Egorov
Modelling of Mobile Nonlinear Frictional Systems

The article describes modelling of mobile frictional systems which allows real estimation of values of required parameters taking into account dynamic characteristics of definite mechanical systems, definite friction units and materials of friction surfaces. It allows considering complex nonlinear interrelation of dynamic processes that occur in frictional contact area and in a mechanical subsystem. The construction of a mechanical subsystem model on the basis of its mathematical model allows investigating interrelation and interference of dynamic processes occurring in a definite friction unit and a definite mechanical subsystem in modelling and natural conditions. Maintaining equal identical conditions of interaction contacting micro- and macroroughnesses provides identical kinds of wear-out and its intensity, current values of a friction factor in natural and modelling conditions. On the basis of a method of the analysis of the differential equations of the object and its model, there have been chosen two equations corresponding to rotary (longitudinal rolling of a body) and forward (to vertical offsets of the first wheelset) oscillations.

V. V. Shapovalov, V. B. Mishchinenko, G. A. Areshjan
Forecast of Frictional Bonds Abnormal Status

There is a problem of short-term or long-term forecasting of abnormal status of frictional bonds in mechanical systems and control of their dynamic characteristics. To solve this problem, we suggest using the status control of tribosystem according to the analysis of integrated estimates (dissipation function, degrees of dissipation, the power losses of frictional system led to an exit and a quadrantic module of coherence), a stability margin on amplitude and phase of amplitude and phase–frequency characteristics (APFC). These estimates influence the given quantity of the peak factor which defines sensitivity of systems of automatic regulation to tribosystem parameters. It is also the sign of transition from one stationary status to another. During tribospectral identification of pre-slippage, the fixing of corresponding integrated characteristics is a signal to give activator of clutch in wheel and rail contact. It allows increasing traction effort of the locomotive and decreasing its speed for the drop of traction capacity of wheel–rail system.

V. V. Shapovalov, P. N. Stcherbak, R. A. Kornienko

Design and Manufacturing Engineering of Industrial Facilities

Frontmatter
Modelling of Cutting Forces in Ball-End Milling

Manufacturing multiple freeform surfaces’ parts, viz. dies, moulds, blades, impellers, metal models, etc., is both one of the most time-consuming and difficult methods of machining processes existing today. Since the surfaces subject to machining have various elements and their shapes are very complex, the material layer removed at the machining process is uneven. The main parameters influencing the surface quality are the values and the directions of normal and tangential components of the cutting force described in the paper. A set of equations stating the interrelation between the normal component of the cutting force and the geometrical parameters of the cutting zone is given. The analytical and later numerical solution of the set of equations allows mathematical modelling of the force parameters during freeform surface machining, which, consequently, will allow for the further investigation concerning mathematical modelling of a surface topology and, as a result, prediction of the obtaining surface accuracy and roughness.

A. V. Vyboishchik
Simulation of Ion Transfer During Electrochemical Shaping by Ultrashort Pulses

In the work, an efficient model of the transfer processes in the electrochemical systems was developed for the case that ultrashort current pulses were imposed. The Nernst–Planck equations with the electroneutrality condition were used for calculating the transfer processes in the diffusion layer, and the equilibrium Boltzmann distribution of ions was assumed in the diffuse layer. This provided a high efficiency of the model. The simulation involved the numerical solution of the Nernst–Planck equations for the diffusion layer and the Poisson’s equation for the diffuse layer. Thus, obtained solutions were conjugated in accordance with all boundary conditions. The time dependences of the electrode potential were obtained for the anodic and cathodic processes. The regions, which corresponded to different scales of time and characterized the charging of bulk electrolyte solution, the charging of electrical double layer, and the transfer processes in the diffusion layer, were observed in these dependences. The specific features of transfer processes under the imposition of ultrashort current pulse (a pulse time of the order of tens of nanoseconds) were studied.

V. M. Volgin, V. V. Lyubimov, I. V. Gnidina
Microprofile Model Form Changing Research at Axisymmetric Deformation with Account of Scale Factor

One of the relevant issues of the machine construction technology is the one of the improving axisymmetric deformation technologies consisting of the consideration of engineering background at surface microgeometry formation. At the moment, the issue of the initial microprofile influence on the surface microgeometry after axisymmetric deformation is insufficiently studied. The research of microprofile form changing at axisymmetric deformation was conducted using the samples with a regular profile having a wedge-like (triangular) section imitating the surface after a turning process. The surface roughness model form changing were researched by the face and back angles at the microprofile bottom with the reduction degrees commensurable with the height of the initial microprofile taking into account a scale factor influence. The paper established the microprofile reduction degree influence on its bearing capacity. The authors proposed optimum parameters for a rough layer pre-obtained with the help of turning. Such parameters allow for the microprofile formation without any hidden defects (cavities) formation. Steel 45 was used as the material for samples.

N. V. Vulykh
Research of Characteristics and Parameters of Cycloidal Gear

One of the most important tasks of modern mechanical engineering is to develop efficient drive mechanisms, possessing high accuracy, security, and significant load capacity at low weight and dimensions. For a successful solution of this problem, the improved research methods and the automation of design process of technical means, providing the improvement of mechanisms characteristics and the choice of optimal construction parameters, are needed. Cycloidal gears are the perspective types of gear mechanisms. They have a number of advantages: the reliability, working capacity in conditions of dynamic loads, high efficiency, the compactness, and large range of gear ratios. Concerning the question of the improving research methods of characteristics and parameters of cycloidal gears is topical. This article presents the automated technique of the calculation of the size of clearances and deformations, arising between teeth and trowels of cycloidal engagement. An analysis of the influence of profile correction at the size of clearances and deformations, and also at the number of teeth, that simultaneously transmit the load, is cited. The software application, developed by the authors, provides a computer-aided creation of models of cycloidal mechanisms with obtaining the required clearances. On the basis of the correction of geometric parameters of the gear, a recreation of management programs for CNC machines has been automatically carried out. The authors presume a further elaboration of developed software application with the aim of its adaptation for the solution of a wide range of tasks of the research and the modeling of constructive and technological cycloidal gear parameters.

Yu. I. Brovkina, A. N. Sobolev, A. Y. Nekrasov
Technological Aspects of Quality and Renovation of Machines

The article deals with the aspects of technological maintenance of the quality of machines with a possibility of their renovation at various life cycles. The conditions under which renovation is economically and technologically effective are presented. Some aspects of the material science approach in solving renovation problems are presented as well as technological methods for hardening machine parts on the basis of various energy sources. The results of the research of metal materials microhardness when processing are given by the laser in a magnetic field. The features of the technology of friction surface restoration are analyzed by thermal drawing methods. The structures of coverings of metal materials providing for the protection against wear with hydrogen are offered. The conditions of passivation of friction surfaces are defined.

P. G. Pyrikov
Raster Marking of Surfaces with Elastic Coating

The marking of critical parts becomes part of the technological process of their manufacture, and since in production and during operation, it is necessary to know the designation of the part, the number, the manufacturer, and other information. The electrochemical marking method forms depressions on the part surface which can become a stress concentrator and reduce the performance of the product. When marking metal surfaces that have a protective dielectric coating according to existing technologies, this coating is removed, and after the application of the information array it is restored, which takes additional time and resources. It is proposed to mark the surfaces with an elastic dielectric coating with a raster electrode tool using rheological fluid. With this method, information on the surface of the part is formed in the shape of convex marks under an elastic coating without compromising its integrity and damaging the surface layers of the part. A mechanism for the formation of information signs is described, and processing modes and an example of applying information are presented.

A. A. Кozlov, A. M. Кozlov, Yu. V. Vasilenko
Cutting Teeth of Non-involute Gears of the Cylinder–Conical Internal Transmission of Internal Gearing

The paper deals with a cylinder–conical internal gearing consisting of an involute cylindrical wheel with internal teeth and a cone-shaped (according to the form of the workpiece) non-involute gear, the axis of which is at the angle to the wheel axis. With the use of these gearings, it is possible to create eccentric planetary transmissions with two inclined satellites which implement large gear ratios (in the power drives 90–500) and having high load capacity with relatively simple design. In their characteristics, they are comparable with harmonic gear, but more reliable. However, non-involute gear teeth have a complex barrel-shaped, getting them theoretically accurate surface difficult. Cutting teeth of the considered gear can be carried out with a sufficient practical accuracy in the machine gearing of the workpiece and the tooth-carving hob as it moves along a certain curvilinear trajectory. The dependencies for determining the trajectory of the axis of the milling cutter when cutting teeth of a non-involute gear of the cylinder–conical transmission of internal gearing are obtained. The movement of the milling cutter along a curved path can be realized in CNC tooth milling machines. In the paper, the example of calculation of a trajectory of motion of the axis of the cutters for cutting the teeth of a crown pinion planetary reducer with internal, helical-bevel gearing is shown. The research results were used in the design and manufacture of planetary gearboxes for various purposes.

B. A. Lopatin, R. I. Zaynetdinov
Mathematical Model of State of Stress in Cutting Area During Synthegran Machining

Synthegran is composite material compounded of an epoxy binder and high-strength mineral filler. Fillers include different fractions of granite macadam with various grain sizes from 1 to 15 mm. Synthegran is used in order to substitute iron casting employed for basic parts of lathes, machines, and tools. Nowadays, the behavior of this material in the process of manufacturing parts and assemblies from it and while machining has not been sufficiently studied yet. Synthegran machining has several features distincting it from similar metal machining. It is explained by characteristic properties and the structure of material to be machined. This article deals with the mechanism of swarf formation during machining of the mentioned composite by a blade cutting tool. Due to the material being fragile, the fundamental principles of the theory of fracture mechanics as well as the theory of metal cutting were analyzed. The mathematical models of cutting process, which allow us to determine state of stress in cutting area and predict the quality of synthegran surface, were proposed. The research demonstrated that peak normal and shear stresses during machining occur below the cutting surface. Thus, during swarf formation, the crack will spread deep into a material surface. Consequently, the quality of the composite surface is fully determined by a trajectory of crack propagation under the formation of discontinuous chip.

T. N. Ivanova, V. N. Tyukpiekov
Specificity of Cutting Tool Wear in Processing of Polymer Composite Materials

The article presents the characteristics of polymer composites processing, in particular, the wear process of the cutting tools. It is revealed that composite materials are difficult for machine cutting and require to apply a high-strength tool material and selection of optimal cutting mode. The important task is to reduce the cutting tool wear speed. To solve the problem, the experiment with a variation of the cutting mode was conducted, and the results showed that the tool wears faster at the high cutting speed and cutting depth. With the cutting speed increase, the intensity of the growth of the wear chamfer increases significantly, and therefore, when setting the cutting conditions, one should be guided by a rational combination of the operability of the cutting tool, the quality of the machined surface, and the processing capacity. These studies have also allowed to establish that the uneven wear process is uneven throughout the length of the cutting edge due to the layer structure of the composite.

D. A. Rychkov, A. S. Yanyushkin, V. Yu. Popov
Diagnostics and Forecasting of Defects in Rotation Details

In the given paper, ultrasonic installation which allows to carry out automatic diagnostics of quality of details of rotation by a method of ultrasonic scanning is offered and described. The machine makes it possible to automatically control the quality of work rolls, to identify the rolls liable to spalling and delamination of the hardened layer using the ultrasonic scanning method. The application of the proposed machine makes it possible to detect the defects in a mill roll at all production stages. The paper offers a description of the software product, which controls the ultrasonic card, and using an ultrasonic sensor automatically generates and receives ultrasonic signals. The obtained results confirm the guaranteed defect detection in the near-surface layer of the mill roll. The application of the proposed machine makes it possible to detect the defects in a mill roll at all production stages.

L. G. Egorova, K. N. Vdovin, O. S. Logunova
Influence of Thermoplastics Advanced Ultrasonic Treatment on Treated Surface Roughness After Turning

The results of experimental studies of a new method for turning billets from thermoplastic polymers such as caprolon and fluoroplastic are presented. The technical essence of the method is in the workpiece advanced processing by ultrasonic vibrations using preliminary machining. Experimental studies were carried out on a lathe which is equipped with an ultrasonic oscillatory system. Roughness level profilograms of the caprolon and fluoroplastic-treated surfaces are used for visual and operational control of the turning process. The results of the experimental verification of the developed method confirmed the expediency of its implementation since the use of advanced ultrasonic treatment during turning of thermoplastics leads to a decrease in the roughness level of the treated surface of the part as evidenced by the values of roughness parameters and the type of chips obtained.

O. Yu. Erenkov, S. N. Khimukhin, A. I. Erukov
Solid Modeling in Autodesk Inventor at Initial Stage of Training of Specialists in Field Mechanical Engineering

The modern approach to the design of engineering objects is based on the development of solid-state models, with a subsequent analysis of their performance: calculations for strength under the influence of static and dynamic forces, motion analysis of links, and other studies. The design documentation, and sometimes the immediate process of manufacturing parts, is created on the basis of the 3D modeling results. The article is devoted to the initial training of students of machine-building specialties in the field of solid modeling and the development of design documentation—the academic discipline “Engineering and Computer Graphics”. The issues of creating drawings on the basis of their solid-state models are considered. Some of the tasks are given, and the peculiarities of their implementation are indicated. The article can be useful to the tutors of educational institutions, as well as engineers engaged in the independent study of 3D modeling methods and their application in professional activities.

V. V. Теlegin, A. M. Kozlov, A. V. Кirichek
Management Mechanism for Continuous Improvement of Production Processes Using Quality Management Methods

The main task of machine-building enterprises is the timely provision of the market with competitive products. The solution to this problem is possible on the basis of continuous improvement of production processes for the manufacture of engineering products based on the use of quality management methods. The manufacturing of engineering products is a complex and time-consuming process consisting of a large number of stages of production of individual units and parts as well as the assembly and testing of all elements. Consequently, a simultaneous improvement of all production stages of engineering goods in the existing production is impossible since this will cause disorganization of the production process as a whole. Therefore, in the conditions of operating production, the improvement of production processes should be carried out step by step starting from the stages that require a priority improvement and using a sound combination of quality management methods that take into account the specific features of the particular enterprise. The variety of quality management methods and quality control tools complicates the task of selecting them for each specific production process. For its solution, it is proposed to use the criterion of Taguchi signal/noise. As a criterion for the effectiveness of implementing the stages of improving the production process using quality management methods, it is suggested to use a dynamically integrated indicator of the quality of the production process. The proposed mechanism for managing the continuous improvement of production processes is considered by the example of manufacturing processes for the manufacture of gas turbine engine pipelines.

V. Yu. Antsev, N. A. Vitchuk, V. V. Miroshnikov
Influence of Chemical Composition of Tough-to-Machine Materials on Grinding Technologies

The main direction of machining of difficult-to-machine materials is the improvement of the cutting process of steels with various physical–chemical properties and alloying elements in combination with heat treatment. The properties of the material parts can affect the receiving quality of the surface layer, so were the causes of tough-to-machine materials influencing the chemical composition and the structure. The studies of the grinding of difficult-to-machine materials focus on synthetic diamonds as having the most stable and highest performance. Based on the studies, the recommendations for the use of the characteristics of grinding wheels and brands are developed for the difficult-to-machine steels. The increase of the grinding depth, cross-feed movement and wheel speed results in the load growth on the blade-edge of the work surface of the wheel. In addition, it causes resistance weakening. Cutting rate increasing allows one to raise the resistance of grinding instrument because slice thickness decreases. The resistance increase also takes place in case of employing a grinding wheel with greater diameter and width. The cutting rate increasing may considerably influence the grinding process because, on the one hand, the process of metal removal intensifies. On the other hand, there can be changes in working conditions for every single blade-edge caused by speeding up sliding and metal deformation. The key factors defining rational machining conditions are the durability of cutting surface, heat flows operating. They provide for maximum possible metal softening of the layer to be cut saving high hardness and resistance of cutting instrument.

T. N. Ivanova
Neural Modeling of the Energy Efficiency Factor for Recuperators (Heat Exchangers) Using Impinging Jets for the Metallurgical Productions and Machine Building

The given work contains a complete application analysis for neural networks of the common logarithm of the energy factor for heat exchangers (recuperators) to heat the air from the heat exchange surface onto which the systems of impact plane-parallel jets are delivered in heating and thermal furnaces in machine building and at the metallurgical plants. The following input signals have been provided: the width of the slot nozzle, the jet axial length, the nondimensional length from the heat transfer surface to the nozzle cut (related to the width of the slot nozzle); the specific (per unit area of the heat transfer) consumption of air. The matching of the target records of the common logarithm of the energy efficiency factor with the output values was carried out (obtained using the artificial neural network in case of the network learning applying a quasi-Newton technique, BFGS, and the method of random increments) for the network structure 4-9-9-9-1. The analysis of regression for the obtained data and target outputs was implemented, and the correlation factors were given. The optimal results with the lesser values of Mean Squared Error and the closest to one of the values of the correlation coefficients were obtained when using the following algorithms: used as the learning function of adaption of the training function for the descent of a gradient with the momentum, as the transfer function—the hyperbolic tangent and the network learning using the quasi-Newton technique, BFGS. The results obtained can be applied in order to optimize or to develop the calculation techniques for the new highly efficient heat exchange devices exploiting the systems of plane-parallel impingement jets as well as for a wider use of the impinging jets technology in various industrial branches such as design and manufacturing for different new technologies including mechanical facilities.

L. Haritonova
Determination of Optimal Conditions for Flat Grinding of 20 Kh Steel Workpieces

Flat peripheral grinding of 20 Kh steel, samples are studied. The authors propose a method of determining optimal conditions for grinding sample surfaces that guarantees obtaining the predefined quality requirements to the machined surface (surface roughness parameter Ra, the absence of grinding burns), while ensuring the maximum efficiency of the process. The mathematical models of the cutting force components reduced to the width of the sample, grinding ratio, and roughness of the machined surface (Ra parameter) are obtained by the method of full factorial experiment of the 24 type, where 4 is the number of factors. The input factors (grinding wheel hardness, depth of grinding, table feed speed, and run reduced to the width of the machined surface) are considered as the optimization parameters of the grinding process. The mathematical models of the output factors are used to limit the range of allowable values of the optimization parameters. The resulted efficiency is an objective function. The optimization of parameters in the range of allowable values is carried out with the view of ensuring maximum efficiency of the process.

V. N. Tyshkevich, V. A. Nosenko, A. V. Sarazov
Increased Durability of Flexible Gear of Harmonic Drive Due to Flexible Bearing Modification

The research object is a harmonic drive with a cam wave generator. A harmonic drive operation is limited by flexible gear fatigue resistance, flexible bearing durability and teeth sides wear resistance. After prolonged use, the wave generator may possibly wear. To increase the fatigue resistance, a refined method of ring gear stress calculation should be developed for the consideration of the drive structural change and parameter impact on flexible gear stresses. The developed mathematical model of a harmonic drive enabled to prove the possibility of flexible gear stress reduction due to a small recess (some dozens of µm) on the outer flexible bearing surface. The obtained dependencies expand the knowledge about the impact of various harmonic drive factors on flexible gear stresses.

I. E. Lyuminarsky, S. E. Lyuminarsky, E. S. Lyuminarskaya
Estimation of Geometrical Torsion Rigidity of Triangular and Rectangular Sections Using Interpolation Method

The article considers the problem on a pure torsion of elastic prismatic beam with arbitrary convex contour in the isoperimetric form. It is proved that for isometric sections with a convex contour, the normalized geometrical torsion rigidity depends on one parameter only—the form factor. The sections in the form of isosceles and rectangular triangles, rectangles, and parallelograms are considered. Graphical comparison of the given geometrical rigidity of the examined sections with the value reciprocal of the form factor displayed the real similarity of these graphs. Analysis of these graphs provides the conclusion that all the range of values of the normalized geometrical rigidity of parallelogram sections is limited from above with values ik for rectangular sections, and from below—for the rhombic sections. Applying the method of geometrical modeling rigidity of the sections by a section form, we suggest the interpolation method to determine the given geometrical rigidity of the sections by the form factor. The obtained results are otherwise satisfactory when performing engineering calculations.

A. V. Korobko, S. Yu. Savin, Yu. E. Balikhina
Determination of Maximum Deflection of Elastically Isotropic Plates with Combined Boundary Conditions Using Scaling Method

As a rule, the problems of statics and dynamics at physical and mechanical modelling of structures are considered separately. In this article, these two types of plate deformations (transverse bending and free vibrations) are considered in its interconnection. The functional dependence maximum deflection—vibration fundamental frequency for elastic isotropic plates of arbitrary form with a convex contour and combined boundary conditions (combination of simple support and clamping)—is obtained. We suggest the method of determination of maximum deflection of full-scale structures in the form of uniformly loaded plates by the vibration fundamental frequency of plate models in the unloaded state obtained experimentally. Applying regression analysis of the solutions which are presented in the scientific and reference literature, an approximating function w0 − ω is plotted. It satisfies all variations of plates with a convex contour and arbitrary boundary conditions (combination of simple support and clamping around the contour) with the error (5–6)%. The article provides the examples of the proposed method application. It shows good accuracy.

V. I. Korobko, N. G. Kalashnikova, O. V. Kalashnikova
Analysis of Methods for Increase of Soundproofing Structure Efficiency for Noise Reduction During Technological Processes of Machinery Production

Industrial noise is one of the factors that accompanies almost any production process. The main sources of industrial noise and the impact of this noise on human health are considered here. The adverse effects of noise predetermine the set of noise reduction measures taken by the designers of structures and technologies, specialists in the field of labour safety and comfort, and protection of the environment. The set of measures aimed at noise reduction is a variety of constructive techniques, technological and protective activities. The methods of protection from industrial noise in its generation source, as well as on the way of its transmission from its source to the subject of protection, are considered. The examples of the use of single-layer soundproofing structures are given. The options for the implementation of multilayer soundproofing structures to reduce industrial noise, consisting of several rigid and elastic layers, are provided. The purpose of the pilot study was to analyse the performance of soundproofing structures in the frequency range. The measurements were made for different types of soundproofing structures at different distances from the source of industrial noise. The results of the pilot study of the efficiency of different types of single-layer and multilayer soundproofing structures are presented.

S. I. Gvozdkova, L. E. Shvartsburg
Question of Creation of General Theory of Deep Holes Machining

The article notes that the development of industry poses the task of creating a general theory of the deep hole machining in the details. It is shown that drilling holes in details largely depends on the dynamic features of the mechanisms and the cutting process. A system of differential equations describing only the longitudinal and torsional oscillations of the cutting part of the tool is given. Using the example of the experiment on drilling holes with a diameter of 16 mm in austenitic, pearlitic steels, the problems associated with the construction of the cutting part of a gun drill, its wear, and the dynamics of the cutting process are shown. In a simplified setting, some features of the hydraulic system of the whole deep drilling machine are described, taking into account the supply of cutting fluid.

L. Mironova, L. Kondratenko, V. Terekhov
Overhaul-Period Renewal of Cement Kiln Rotary Drive

The article describes a sudden problem of unplanned failures of the kiln drive due to the destruction of the barb bolts of pillow block bolts. However, the evaluation of the bolts’ state according to the conditions of long-term strength did not confirm the loss of their operability. The model of gradual bolt failures has been developed using the kinetic approach to the destruction of structural materials and the thermodynamic condition for the solids strength in order to theoretically substantiate and solve the problem. The cause of the destruction in a barb bolts material was established after approximately 4-year operation on the basis of the theoretical analysis. Calculations showed that at the end of this lifetime the energy density of the material structure defects reaches a critical value corresponding to its melting enthalpy and leads to its destruction. The undertaken analysis made it possible to propose and justify two new design versions of the kiln rotary drive with almost complete unloading of the pillow block bolts. One of them is connected with the transfer of the drive to the opposite side; the other implies a direction change in the kiln rotation. The second version of the drive reconstruction turned out to be technically and economically feasible as well as the least prolonged. It is commissioned into commercial operation.

Aleksei V. Antsupov, Alexander V. Antsupov, M. G. Slobodianskii
Model of Failure Due to Wear Process for Mill Rolls Universal Spindle Couplings

Practice has shown that one of the main reasons of lower technical and economic performance of wide-strip hot-rolling mills is a very short useful life of the universal spindle couplings, and a substantial extension of their durability is required. Therefore, in order to find an effective solution to this issue as early as at the phase of design, we have developed (and presented in this article) an analytical model of couplings gradual aging (wear) process depending on the criterion of bronze bearings wear resistance. The model provides a method for forecasting the condition of couplings without running model testing or full-scale experiments. It was built using the main principles of evaluation of technical objects parametric reliability and the basic dependencies of electromechanical theory of stationary tribo-systems pertaining to the aging process. On the basis of our model, we have developed an algorithm for calculating the expected life of universal spindles. The algorithm can be used as an instrument for analyzing various alternatives of couplings design and selection of the one with the best durability. The model validity has been proved through comparison with durability calculations provided in well-known research papers.

Alexey V. Antsupov, V. P. Antsupov, Alexander V. Antsupov
General Principles and Design Strategy of Optimal Reconfigurable Manufacturing Systems

The general principles and the strategy of design of the optimal reconfigurable manufacturing systems (RMSs) are given in this article. It is shown that an indispensable condition of creation of optimum RMS is creation of the bank of the design information formalized in the form of a technological code of the product accumulation models of products and their elements, and also providing a two-way operatively communication between it and all manufacturing systems (MSs). The general algorithm of the choice of an optimum configuration of MS with the detailed description of all main stages is offered. The authors proposeed a scheme of distribution of a flow of orders in which it is offered to distinguish three types of structure of technological processes: parallel, consecutive, and mixed, and four levels of hierarchy of production: sectoral, enterprise (plant), shop, and site. The general algorithm of the choice of an optimum configuration of MS is developed and described in detail.

A. Kapitanov, V. Mitrofanov
Use of Vibro-acoustic Monitoring for Stabilization Stress–Strain State of Surface Layer of Workpiece During Cutting

The part surface quality directly affects the performance properties of the part, such as environmental resistance, reliability, and durability. The cutting tool wear is one of the dominant factors affecting the formation of the surface layer. The paper is devoted to monitoring of the effect tools wear under the deformation of the surface layer of a part by means of analyzing vibration signals, which are accompanied cutting. The tests were carried out during tool turning in different states with a simultaneous recording of signals from the accelerometer and then, studying the deformations of the surface layer of the parts. We used a grid method to study the deformations. As a result, the relationship between the signal parameters and the accelerometer was established with the intensity of deformation of the surface layer. We proposed a criterion determination technique for the failure of an instrument to change the shape of the vibration signal spectrum. We showed the necessity to exclude intense self-oscillations during cutting.

M. Kozochkin, D. Allenov, I. Andryushchenko
Model and Analysis of the Grinding Wheels Transformation in Double-Disk Grinding

The article is dedicated to double-disk grinding (DDG)—efficient and prevailing tooling method for processing workpieces with parallel end surfaces including bearing rings and rollers. At grinding of the flow of blanks, such as rings and rollers, starting from a certain point in time, there is an increase in processing errors and their out-of-range tolerance. One of the main causes is the uneven wear of the grinding wheels (GWs). To solve the problem of increasing the stability of the rational form of GW, the following tasks were set and solved: (a) development of a mathematical and simulation model for the transformation of the generating surface GW for two basic DDG schemes: with circular and rectilinear feed; (b) theoretical and experimental analysis of the regularities of GW transformation. As a result of theoretical and experimental studies, a typical shape of the worn-out surface of the GW is established for grinding the ends of the bearing rings. It is established that grinding wheels with a modified parabolic profile have better shape stability than flat ones.

L. G. Vainer
New Generation Magnetorheological, Magnetodynamic, and Ferrofluid Control Devices with Nonstationary Electromagnetic Fields

Improving energy efficiency of devices and systems has economic and ecological importance. Applicable hydraulic, magnetorheological, and magnetodynamic control devices consume large amounts of energy, therefore, perfection of their constructions and optimization of working processes are important research tasks. The use of magnetorheological, magnetodynamic, and ferrofluid control devices with nonstationary electromagnetic fields reduces power consumption of drive systems, increases their accuracy, reliability and durability, and raises operating temperature and pressure. The paper presents variations of original constructions of new generation magnetorheological and magnetodynamic devices with rotating and helical control electromagnetic fields, which are used for the regulation of fluid flow characteristics. The application of such regulating devices cannot only improve energy efficiency; it can also increase operating pressures and reduce dependence on temperature factors of their characteristics. Installations of ferrofluid control elements with nonstationary electromagnetic control fields in hydraulic devices contribute to increase in energy efficiency of hydraulic systems and improve their performance. Similar hybrid hydraulic systems have higher response rate to control signal and maintain stability of flow characteristics. Hybrid hydraulic systems include simple geometry of operating cavities and exclude movable mechanical elements. The constructions with movable mechanical elements have significant changes in geometry of operating cavities by influence of erosion processes. Original hybrid hydraulic device construction is presented in the paper. Developed magnetorheological and magnetodynamic devices also have simple geometry of operating cavities. The simplification of structures of devices and systems obviously decreases material consumption for their production, speeds up technological processes, increases profitability of enterprises, and reduces negative impact on environment.

K. V. Naigert, V. A. Tselischev
Technological Peculiarities of Chemical Heat Treatment of Alloyed Steel Gears

Gears made of various steels are chemical heat treatment for greater strength. The strength of cylindrical and bevel (hypoid) gears is evaluated by contact and bending strength of their teeth. The strength of alloyed steel gears greatly depends on the chemical heat treatment applied. The achieved values of the strength of alloy steel gears largely depend on the applied chemical and thermal treatment. The best performance in cylindrical and bevel (hypoid) gears of alloyed, low-carbon steels by contact and bending strength of the teeth is obtained by chemical heat treatment, including carburizing and hardening. To reduce the deformation of the teeth and the base surfaces of vacuum carburizing processes with alternating short cycles of saturation and diffusion followed by hardening with inert gas—nitrogen or helium under pressure. The paper analyzes the conditions of vacuum carburizing with subsequent pressurized-gas quenching. Vacuum carburizing and high-pressure gas hardening systems with a capacity of 100–200 kg/h should be used in mass and large-scale production in the machining production line, ensuring the continuity of the process. It presents the results of experimental studies of how the necks and the rims of hypoid wheel shafts are affected.

A. S. Kalashnikov, P. A. Kalashnikov, I. I. Marushchak
Synthesis of Nanostructured Composite Coatings in Arc Discharge Plasma

In this paper, we consider the results of the investigation of complex composition multilayer vacuum ion-plasma nanostructured coatings based on carbides and silicides of metals. The results of the studies of corrosion resistance, thermal stability, and heat resistance, as well as the results of tests on the microhardness of formed coatings, are presented. The developed technology for multilayer nanostructured vacuum ion-plasma coatings on the basis of titanium carbosilicides with improved performance characteristics is presented. It includes several stages: preliminary surface preparation before the process of coating synthesis, preliminary surface cleaning using a high-current diffusion discharge, surface cleaning with ions of the cathode material, synthesis of nanostructured coatings, with alternating thin layers of variable hardness and different composition and subsequent cooling with the possibility of heat treatment, for example, subsequent thermal annealing.

N. A. Suhova, S. R. Shekhtman, M. Sh. Migranov
Development of Methodological Recommendations for Selection of Flexible Abrasive Tool by Performance Indicator

The results of the development of methodological recommendations on application of specific characteristics of tools on flexible basis (FAT) by performance indicators, issued by FAT passports, are given. The results of the development and selection of FAT indicators to correctly reflect the physical essence of the FAT processing are shown with a clear delineation of the set of indicators for the purpose of tools; the estimation of operational properties of abrasive tools on a flexible basis for roughing and finishing grinding operations is given; the results of determining the complex of the minimum necessary and sufficient number of evaluation indicators are shown. It is made clear that testing the workability of passports of various materials using grinding belts during the year has proved their effectiveness in designing the technology of manufacturing parts with a flexible abrasive tool, and the correction of cutting modes according to the FAT performance indicators has proved their practical importance.

N. V. Syreyshchikova, E. N. Yaroslavova
Structural and Kinematic Analysis of a Shaper Linkage with Four-Bar Assur Group

This study provides a structural and kinematic analysis of the shaper linkage, which includes a four-bar Assur group with three levers. The linkage structural analysis has been carried out in three cases when different driving links have been chosen. A four-bar Assur group has been separated out from the linkage’s structure in the first case, and dyads PRP, RRR, and RPR have been separated out in the second and third cases. The kinematic analysis of the shaper linkage has been carried out for the case when a four-bar Assur group forms a part of its composition. The study provides 3D modeling of the shaper linkage with reproduced trajectories and coordinates data of the distinguished points of movable links with the regard to specified dimensions. The results of the study can be used in kinetostatic and dynamic analysis of the shaper linkage. The research results can be also applied in a design of planing machines and shaper linkages as well as in structural synthesis and analysis of novel planar mechanisms.

A. Fomin, S. Kiselev
Dependence of Roughness Parameters of Workpiece Surface on Structural Characteristics of Grinding Discs

We have considered the issues of how structural characteristics of grinding discs influence the roughness of the processed workpiece surfaces. The analysis of the known research about dependences of roughness parameters of polished surfaces on the disc grit, hardness and structure has been given. The technique to determine the optimum disc hardness which is boundary on the maximum value of the roughness parameter has been demonstrated. The functional dependences of the roughness parameter Ra on the disc structure characteristics, the cutting mode and the processing conditions have been established for flat, round external and cutin grinding.

S. A. Kryukov, N. V. Baidakova
State of Problem of Technological Support of Workpiece Surface Quality During Grinding

Here, are considered the known papers on technological quality assurance of parts surfaces in abrasive processing. The analysis of these research and the issues raised have shown that the solution of tasks related to improvement of the surface layer quality, accuracy, and durability of parts is an actual and promising direction for further research. The basic ways of the decision of a problem of improvement of the part processed surfaces quality are defined. The general disadvantages of the existing empirical dependencies for determining the roughness in different methods and conditions of grinding of the parts surfaces are noted.

S. A. Kryukov, N. V. Baidakova, P. Y. Bochkarev
Physical and Mathematical Model of the Process of Face Grinding of Rails with Abrasive Wheels Operating at Speed of 50 m/s

At rough grinding, the rate of the abrasive mass loss by the wheel (self-sharpening) depends, from the one hand, on magnitude of the power load accruing to each operating grain of the wheel, and from the other hand, on the strength and quantity of the bonding determining the hardness of the wheel, i.e., its capability to keep the grain from being torn out from the bonding until obtaining the biggest worn place. It is necessary to determine practical force operating upon the grain. However, for each power load on different types of rails, it is necessary to select a different hardness of the wheel, which ensures the retention of blunted grains at various power loads on the wheel. In this case, the increase in the hardness of the wheel, obtained by increasing the volume of the bonding and reducing the porosity of the wheel, reduces the self-sharpening of the wheel (smaller loss of blunted grains), which leads to the termination of cutting and metal removal, strong heat generation, and metal burns. As a result, we invented the dependence that makes it possible to determine the practical force operating upon a single grain of an abrasive wheel force taking into account the operating modes of the real grinding machine, the properties of the treated surface, and the wheel structure.

T. N. Orlova, I. Y. Orlov, N. S. Hvan
Chip Formation Mechanism at Metal Grinding

The authors proposed and described the method of chip formation a metal grinding based on the representation of the conductivity of perturbations with a fixed velocity in a medium as a part of space. The separation of the cutting micro-chips results from the displacement of the shock wave in front of the abrasive grain resulting in a loss of the shear stability of the material in the local zones of the stress concentrators, the development of the rotational nature of deformation with the structure fragments turning around the axis perpendicular to the direction of displacement of the ‘wheel–billet’ contact zone.

V. M. Shumyacher, A. V. Slavin, O. G. Kulik
Monitoring of Grinding Process with Help of Automatic Measuring Complex

To determine the characteristics of an abrasive tool, the composition of lubricating-cooling liquids (LCL), and grinding modes at the stage of the technological process of abrasive processing development, we created the software-automatic and automatic test complexes that allow prolonging express tests. Let us lay the foundations of the computer-aided design system. The principle of operation of an automated complex is based on statistical analysis of output energy parameters of technological equipment operation. We developed a methodology for the design of grinding wheels which are based on the data of monitoring the grinding process with the help of the original automated measuring complex.

V. M. Shumyacher, A. V. Slavin, P. Iu. Bochkarev
Intensification of Technical Grinding Modes by Managing Physical Processes of Chip Formation

The article describes the control mechanism of interaction between the abrasive grain and the processed metal, the interaction being based on the hypothesis of the shift in the phase transition points under the Clausius–Clapeyron’s law, when the temperature and pressure rise at a high speed in the contact arc between the inclined blunting site of the abrasive grain and the metal. The metal separated from the bulk and consolidated like this, shortly remaining extra hard at the melting temperature, is itself capable to make an edge micro cut of the chips when it moves together with the grain at a speed of 10−5–10−6 s and higher.

O. G. Kulik, E. D. Illarionova
Tools for Electrical-Discharge Hole Drilling

Multi-electrode electrical-discharge drilling of holes and grooves is widely used in aerospace manufacturing. We herein consider the problem of tooling the operations of simultaneous electrical-discharge drilling of multiple small-diameter holes in filter-type parts. Given the required area of the nominal bore and the required dimensions, we designed a filter with rhombus-shaped holes with an external diameter of 0.25 mm and apical angles of 65,030′ and 114,030′. New designs for electrode tools are proposed and the process of making and using those is described. Assembling a multi-electrode tool for the part took 330 min. Using standard 300 mm rods was enough to make 218 filters with this tool. Technical and economic calculations show that using multi-electrode setups depends on the annual production of the same part. For each specific product, one can calculate the critical annual production value, which is necessary for such multi-tool setups to be cost-effective.

A. A. Gruzdev, Yu. A. Morgunov, B. P. Saushkin
Specifics of Reaming Allowances of Different Materials with Indexable Throw-Away Inserts

We have developed a mathematical model that takes into account walking of a reamer with indexable throw-away inserts when processing various materials. This model allows us to predict the accuracy of hole making by the tipped tool. Within the framework of the research, we plotted and calculated the material layers, which are cut by each cutting tip. We analyzed and compared the developed models of the cut layers and the mathematical model. The obtained data allow us to divide the material into two types according to its ability to be processed with a tipped tool. Shaping diagrams of cut material layers were plotted and the existed shaping diagrams of the reamer with indexable throw-away inserts were analyzed. The calculations and comparisons allowed us to conclude that the mathematical model is consistent and can be applied in production units at machine-building enterprises.

I. P. Deryabin, A. S. Tokarev
Experimental Optimization of Cutting Modes for Milling Based on Vibroacoustic Analysis

The paper proposes a method for setting the cutting parameters for metal-cutting machines. This method is based on performance estimation and a vibroacoustic analysis of the cutting process. Before experiments are carried out, a three-dimensional finite-element model of the machine is built, and then the NX Advanced Simulation module is used to calculate the actual machine frequencies. First, we set the basic and the maximum values of the cutting parameters. Then, we build an experimental matrix and carry out the experiments on its basis. The matrix is based on a Taguchi method to reduce the number of necessary experiments. The experiment is designed to find out the maximum amplitude as well as the maximum amplitude frequency of vibroacoustic oscillations. Then, we estimate experiment-specific performance. Further, we set the optimal cutting parameters to ensure the maximum performance and vibration stability of the cutting process. This is done by reference to the Harrington desirability function. The method is versatile and applicable to any machine or material.

R. M. Khusainov, P. N. Krestyaninov, D. D. Safin
Selection of Priority Production Technology Based on Comparative Evaluation of the Oil and Gas Equipment Working Resource

The purpose of this article is to provide the largest working resource of oil and gas equipment by selecting a priority manufacturing technology. We propose to use the plasticity resource of the material as a criterion for the choice of technology. Manufacturing technology which provides the greatest plasticity resource of the material should be recognized as a priority. We propose a new procedure for comparing technologies using information on the plasticity resource of metal at the final stage of fabrication of the product. This procedure includes the following steps: (a) cutting samples from the regions of the structure with the most deformed metal, (b) determining the mechanical characteristics of the metal using the penetration method based on ESPI, (c) testing the samples for crack resistance, and (d) determining the plasticity reserve of the material. At the last stage, the concept of a two-stage process of damageability accumulation is used. The proposed procedure excludes a detailed analysis of individual technological operations. The use of this procedure will simplify the comparison of the different technological processes for the products manufactured and the selection of priority technology.

A. G. Ignatiev, V. V. Erofeev
Statistical Processing Method of Cylinder Measurement Results

At enterprises, when producing and repairing machine parts, it is necessary to introduce new methods and control tools including the most effective (as of today) coordinate measuring machines (hereinafter CMMs) of different configurations, types, and sizes. CMM is set behind the machining centers at the end of the line section or the production line for final inspection of parts and products. Underlying the CMM operation coordinate measurement method is the most versatile and can be used effectively for automated control of a wide range of components. Coordinate measurements are the measurements of the geometrical parameters of the object by determining the coordinates of separate points on the object surface in the adopted coordinate system which may be rectangular (Cartesian), cylindrical, and spherical. These measurements are followed by the subsequent mathematical processing of the coordinates measured to determine linear and angular dimensions, shape and positioning deviations of surfaces. All these are indirect measurements as by using standard measurement strategies we obtained coordinate values of separate points belonging to the controlled surface as primary data. In this paper, we propose a method for determining the surface of rotation by the measured coordinates. To do this, the uniform noise is superimposed on the given test surface, and then this initial surface is reconstructed according to the coordinates obtained and the error of the reconstructed surface deviation from the given one is estimated.

E. A. Herreinstein, L. I. Korolkova, N. Mashrabov
Shafts Reliability Assessment in Accordance with Criteria of Fatigue Strength Under Random Load Conditions

The paper considers an improved method of shaft strength reliability calculation based on random values and nonparametric statistics computer simulation methods. The probability of shaft failure-free operation under random load condition is estimated by the fatigue strength resistance criterion. In this case, the safety factor is defined by a sample obtained using nonparametric generators. The paper considers four standard load conditions described by normal, equally, gamma-, and beta-distribution, and also random distribution defined by the user. A probability density function of the safety factor is recovered by the Parzen–Rosenblatt method. All algorithms are realized in Mathcad processor software. The authors carried out computer simulation which showed the difference in the shaft failure probability at different load condition varying from 0.702 to 13.936%. The proposed method allows one not only taking into account actual laws of external load distribution, but also recovering a factual function of safety factor density distribution as well as a failure-free operation probability in accordance with it.

K. Syzrantseva, L. Chernaya
Theoretical Foundations of Vibration Processing Modeling

The results of the mathematical model development describing the motion of a load mass in a U-shaped container of a vibrating machine are presented, allowing one to take into account the influence of the field inhomogeneity of the oscillation trajectories of the container walls on the process productivity. The dependence of the determination of the circulating velocity of the working medium and the power expended on the processing of the product depending on the operation modes and the structural arrangement of the vibrating machine units is obtained, which determines the conditions for ensuring the stability of this movement, taking into account the mutual arrangement of the main units of the vibrating machine—vibration exciter and container. The possibility of increasing the operational properties of products as a result of vibrating treatment on finishing-peeling and strengthening operations on machines with a U-shaped container without a rigid kinematic connection between the elements of the technological system with increasing process productivity due to an external field-induced vibration excitement, which is a superposition of two planes-parallel fields: solenoidal-potential and vortex are theoretically proved.

E. Levchenko, Yu. Deykun, Yu. Moroz
Modeling Stress State Carbide Dies for Hexagonal Rods Production

The main cause of the tool failure is the collapse of the monolithic die. In order to determine the cause of the die collapse, the modeling of the hexagonal rod drawing process was performed. Based on computer simulation using the finite element method, the qualitative and quantitative distribution of the radial, circumferential, axial stresses along the length of the working channel of the die for drawing hexagon has been determined. The plots of stress distribution of a drawing tool are constructed. The reasons for the collapse of the hexagonal rod drawing tool are established. A new design of the hexagonal bars drawing tool in the form of a sectoral die are presented, determined by the stress–strain state of the polyhedral sectoral die. The implementation of the die in the form of sector elements excludes the concentration of tensile circumferential stresses in the longitudinal section of the die. The new design of the tool allows increasing the durability of the die.

S. A. Malakanov, O. S. Zhelezkov
Automation of Technological System Diagnostics by Parameters of Quality of Surfaces of Machined Parts

The current issues of automation of diagnostic processes of technological systems (DTS) in terms of quality parameters and operational properties of surfaces of machined parts are considered. The concept of the proposed diagnostic method includes four stages related to the DTS plan design, the implementation of the DTS, the measurement of surface quality parameters using information and measurement systems, or the diagnosis of performance characteristics on special test bench, processing and statistical analysis of diagnostic results is presented. An example of the technological system diagnosis for processing flat surfaces of parts on a CNC face milling machine by a composite 10 and subsequent surface plastic deformation by diamond burnishing or roll burnishing with a spherical indenter. The schemes of automated surface treatment of samples in the TS diagnosis are presented. The types of measuring systems for measuring geometrical quality parameters of machined parts surfaces are indicated. A brief description of the system of microstructural analysis of surfaces used to diagnose TS according to physical and mechanical properties is given. As an example of the diagnostics of the operational properties of the surfaces of parts, a method for estimating the relative wear resistance of a surface treated with diamond burnishing is presented. The questions of the application of special test benches, where the testing conditions of joints of parts are similar or reproduce real operating conditions, are considered. A typical structure of an automated system for diagnosing a TS including test benches and control systems, data collection and processing is presented.

M. N. Nagorkin, V. P. Fyodorov, E. V. Kovalyova
Computer-Aided Design of Die Tooling for Large Parts of Airfoil Profiles

The article describes the developed computer-aided design (CAD) systems of die tooling for large parts of airfoil profiles made of aluminum alloys characterized by a high degree of unification and integration which makes it possible to reduce the design time for die tooling tenfold. The paper gives a special focus on the analysis of the design object and the structure of information support of CAD systems of die tooling of airfoil profile parts. All in all, it is possible to develop the means of providing a complex system that performs the design and documentation of blank structures, the necessary technological tooling and the formation of programs for milling the dies on machines with NPC due to the computer-aided design for the blank production objects in large-sized airfoil profile parts. The use of the proposed methods and developed means of computer-aided design of objects of technological preparation of blank production makes it possible to reduce the time of preparation of production by 15–20 times while improving the quality and accuracy of design solutions. Thus, created on the basis of the introduction of computer technologies, advanced domestic and foreign experience, CAD DT of large-sized details of the airfoil profile contribute to the solution of the urgent problems of production modernization.

I. N. Khaimovich
Determining Precessional Gearboxes Efficiency of Manual Pipeline Valve Drives

The drives based on gears are used in machines and mechanisms of a wide variety of engineering products. The article analyzes the characteristics of modern manual drives for pipeline valves manufactured on the basis of two-stage spiroid gearboxes. These drives have an extremely low efficiency and a high starting torque which often prevents pipelines from fail-safe opening or closing under harsh operating conditions. It is shown that the drives developed on the basis of bevel precessional gears can significantly increase the efficiency. The paper describes an original method for determining the efficiency of the bevel precessional gears with a small shaft angle. Gearboxes in its design contain two bevel precessional gears. Verification of calculation results is performed based on the available experimental data of tests of the precessional gearboxes of similar structures. The authors discovered that the bevel precessional gearboxes efficiency is 2.5 times higher than in double-stage spiroid gearboxes with the same gear ratios.

V. Syzrantsev, A. Pazyak
Engineering Calculation of Axial Force Acting on Rotor of Electric Pumping Unit of Space Thermal Regulation Systems

The article covers the method of calculating the axial force acting on the rotor of centrifugal electric pumping units used in spacecraft thermal regulation systems. The units shall have a long operational life numbering tens of thousands of hours of continuous operation. Their reliability of the design, precise calculation of radial and axial forces acting on the unit rotor are subject to increased requirements. Precise calculation of forces ensures a correct selection of the type and geometry of bearings in which the rotor is installed. The existing methods of calculating axial force in centrifugal blowers are based on the model of the non-flow type current of working medium in lateral gaps between the unit impeller and body. They use the assumption that the working medium behaves like a solid rotating body. In real designs of centrifugal electric pumping units used in spacecraft thermal regulation systems, current in the gaps is from the periphery to the center of the impeller, so the current is flow type. This essentially changes the nature of the static pressure distribution over the impeller radius, on which the value of axial force depends. Incorrect assumption of the non-flow type of working medium in lateral gaps results in large errors upon calculating the axial force. This paper provides the results of the experimental determination of the static pressure distribution diagram in the lateral gaps between the impeller and the unit body. The approximation of experimental data had been made, on the basis of which a simple algorithm of calculation of axial force was developed increasing the accuracy of calculations.

A. Bobkov
Assurance of Quality Indices of Technological Processes of Form-Shaping During Preproduction Stage

Quality indices of technological processes of form-shaping in general and of machining, in particular, determine to a large extent the competitiveness of these processes and play an essential role in assuring environmental and industrial safety. The most important quality indices of these technological processes are the indices characterizing vibrations and associated noise during the implementation of technological processes. Besides, from the point of view of safety, the issues related to the rational selection of LCTA are of considerable importance. To improve the safety of technological processes, these issues must be solved as early as at the preproduction stage. The issues of improving environmental and industrial safety of technological processes of form-shaping basing on the analysis of vibrations propagation, vibrations prediction, and also the methodology for rational selection of LCTA are discussed in the article. The mathematical models of propagation of vibrations in the structural components of the equipment were developed, and the problems of applying these models for the prediction of vibration levels at a preproduction stage are discussed. The issues of creating a comprehensive criterion for LCTA selection are considered, being a tool for rational selection of LCTA and of the systems for LCTA application. The developed information retrieval system “ECO LCTA” is presented, which includes the database and ensures rational selection of LCTA.

L. E. Shvartsburg, E. V. Butrimova, O. V. Yagolnitser
Investigation of Cutting Processes and Surface of Plastic Deformation in Environment of LCTE with Nanosize Antifriction Particles

In the article, the authors examine the possibility of using the effect of selective transfer (wearless friction) in technological processes and operations of handling, providing for a significant reduction in cutting forces and deformation within the machining of parts. This, in its turn, reduces the energy intensity of technological operations and significantly reduces the cost of manufacturing machine-building products. In addition, the wearout of the tool and its consumption are reduced for manufacturing of a given batch of parts in the production cycle. An effective method of smoothing out details with replaceable polyhedral plates is proposed with a change in the way the tool is installed, and the authors designed a special device to change the position of the tool relative to the workpiece in three coordinate planes. The regularities of the formation of microgeometry during cutting and smoothing of parts with replaceable polyhedral plates were experimentally investigated. The optimum concentrations of the Valen additive with nano-sized antifriction particles were determined to obtain the minimum height of the microgeometry on the treated surface of the part.

V. A. Kuznetsov, A. V. Shchedrin, A. V. Korovin
Choosing Transmission Gearset for Agricultural Aggregates Based on Energy Consumption

Performance is a key indicator of agricultural aggregates (AgA), which are tractors aggregated with trailing or mounted implements. What determines AgA performance in plowing is its travel speed and the actual tangent thrust force. Both parameters depend on the gearset, the number of gear modes and gears, as well as the required engine power. The paper dwells upon a method alternative to the existing methods of determining the gearset and gear ratios for gearboxes in agricultural tractors. It is proposed to choose the gearset based on the energy consumption and the functional purpose of an AgA. For a wheel engine AgA based on a Kirovets K-744R-05 tractor, we herein determine the engine power and gear-specific reserve power as well as the transmission gear ratios and gearset which enable the unit to overcome temporary overloads without switching to a higher ratio gear while meeting AgA performance requirements. Minimizing the energy consumption of performing a specific operation reduces fuel and operating costs which ultimately lowers the costs of agricultural products.

V. P. Antipin, M. Ya. Durmanov, O. A. Mikhaylov
Energy and Fuel Consumption of Agricultural Aggregate

The efficiency of an agricultural aggregate (AgA), i.e., a tractor combined with a trailing or mounted implement, consists not just in performance but also in the consumption of fuel per unit of production, or per a hectare of treated soils. The design can be optimized and improved in terms of their quality by developing and implementing practical methods for assessing the efficiency of AgA; this problem is especially relevant when designing a tractor. Energy used to actualize tangent thrust force has to be taken into account; a method which can be used to estimate not only the regular and dynamic components of such tangent force but also the hourly fuel consumption when designing an AgA. Simulation results are presented as the state surfaces of the frequency response (FR), the AgA tangent thrust force, and hourly fuel consumption for variable design parameters. The volume bound by the tangent force state surfaces and the coordinate axes is deemed to be the energy a part of which is spent to actualize the regular tangent force component, whereas the rest is lost as the dynamic tangent force component. By sectioning the FR state surfaces in the longitudinal-vertical plane at any fixed regular AgA travel speed and for the entire range of leading wheel load oscillation frequencies, we can calculate the regular and dynamic components of the tangent force, as well as the hourly fuel consumption. This paper dwells upon the plowing operation of a Kirovets K-744R-05 tractor with a PUN-8-40 plow operating on light soils.

M. Ya. Durmanov, B. G. Martynov, S. V. Spiridonov
Effect of Tool-Operating Mode on Circularity Deviation in Multilobed Turbine Rotor Journal Restoration with Location on Bearing Bottom Half

A progressive method of a worn turbine rotor journal restoration is machining on mounting bearing of turbine plant directly. Grinding head machines rotor journal moving to its axis while the restored journal in its rotation is located on the bearing bottom half. Thus, rotor center position keeps changing, thus, a required circularity accuracy is not achieved. The best law of grinding head radial feed speed variation is one of the methods providing machining accuracy increase. The effect of feed variation on machined surface circularity accuracy for various numbers of worn rotor journal cross section lobes is investigated. The generation of geometry computer modeling using voxel approach has detected that feed variation practically has no effect on circularity accuracy if lobes number is even. However, for the machining of rotor journals with a three-lobed radial section, the sine variation of the radial tool feed is efficient. Machining accuracy has been increased by 20% compared to the case of machining at constant feed. In all cases, using the same number of workpiece spark-out revolutions as the number of workpiece revolutions at constant tool radial feed has an essential effect on circularity accuracy.

A. V. Shchurova
Improved Axis Determination Method for Calculation of Virtual Pitch Thread Diameter Using a Point Cloud from CMM

Thread gauges are widely used to obtain the values of complex parameters of thread surfaces. The virtual pitch thread diameter (VPTD) is the main standard complex thread accuracy figure. The author has previously published the method of VPTD calculation using the data obtained from the coordinate measurement machines (CMM). However, following this procedure, the thread axis position is considered as a-priory known. It is clear that the axis position is not always known in practice. This limitation makes application of CMM for thread accuracy estimation rather difficult. Later, the author has developed a procedure to detect a part thread axis location. However, this procedure is not accurate enough, in particular, for a short thread. The present paper describes the improved procedure to calculate arbitrarily located thread axis. The procedure includes two stages. The first stage is the determination of average coordinates of the points obtained from CMM for end basic segments. At this stage, the corresponding parallel translation of the points forms circular turn. The second stage is the detection of axis inclination angles and axis turn to these angles to its ideal location. The procedure has been checked by computer calculations, which prove sufficient reliability and accuracy of the accepted approach. With the use of this improved procedure of the thread axis detection, the VPTD is further calculated using a previously published method.

I. A. Shchurov
SPH Modeling and Experimental Study of Unidirectional Fiber-Reinforced Composite Cutting

At present, unidirectional fiber-reinforced composites (UD-FRC) are widely used. The machining of UD-FRC workpieces has some characteristic features. Thus, homogeneous materials cutting experience may not be used directly. One of the problems of UD-FRC machining is interfacial debonding between fibers and matrix at cutting wedge punching-in which results in surface quality deterioration. Therefore, prediction of the obtained surface quality is a vital problem. A rational selection of tool geometry results in debonding reduction. It is reasonable to apply numerical calculations methods as a pilot research stage. In the present research, the results of an SPH method modeling of UD-FRC workpiece machining are given. For the verification of the obtained results, experimental studies have been conducted. A qualitative agreement of modeling and experimental results proves that SPH method application is expedient for UD-FRC workpiece machining modeling.

I. A. Shchurov, A. V. Nikonov
Strengthening of Low-Alloyed Steels by Carbides During Carbon-Black-Gas Carburizer Cementation

The technology of thermochemical strengthening of widely using low-alloyed steels 50HG, 50HF, and 50 HGF by carbides is proposed. The technology provides the self-sharpening of cutting tools during the organic material processing and consists in its saturation by the cementite followed by heat treating as the hardening with medium-temperature tempering. The influence of cementite particles on wear resistance of the cemented layers was investigated. It is shown that alloyed cementite can be applied to surface hardening of the details of tillage machines and tools for organic materials cutting.

N. Kanatnikov, O. Ivanova, G. Harlamov
Dynamics of Spindle Assembly Metal-Cutting Machine Tool with Anisotropic Elastic Support

The article is devoted to the consideration of bending and translational-angular vibrations of spindles of metal-cutting machine tools. The features of the development of dynamic models associated with the significant difference in the values of the stiffnesses of the front and rear supports and the anisotropy of their radial rigidity are noted. The results of the investigation of the effect on the anisotropy of the radial stiffness of deviations from the roundness of the landing surfaces of the shaft and the shell of the bearings are presented. It has been shown experimentally that the stiffness of the front support of the spindle assembly of the lathe has an anisotropy. For the hodograph of stiffness in the form of ovality, analytical expressions are obtained for the natural frequencies of bending and translational-angular vibrations. It is shown that the presence of anisotropy of the stiffness of spindle supports leads to the appearance of a range of natural frequencies of the spindle which significantly complicates the implementation of diagnostic measures. The results of the estimation of the influence of the elastic characteristics of spindle supports on the assembly of the magnitude and range of the resulted stiffness coefficients and the frequency of the natural translational-angular vibrations are presented.

A. F. Denisenko, M. V. Yakimov
Informative Value of Measurements for Quality Management of Auto Parts

The end result of applying many modern methods of quality management is the development of corrective measures to intervene in the process in the form of general recommendations, without specific measures. Only for the sake of assessing the stability of the process according to one measure, the standard recommends conducting more than thousand measurements, which in no way can be recommended for the current production. As a result of the research, it was established that the methods of statistical management of quality indicators, correlation analysis, and other frequently used methods are extremely ineffective, in which corrective measures are developed after additional engineering procedures. We also proposed criteria for measuring the effectiveness and efficiency of analyzing measuring information. Measurement effectiveness indicator—the complexity of planning corrective actions based on measurement data. Efficiency is the laboriousness of carrying out the measurements themselves and analyzing the data. The increase of these indicators is ensured by: the preliminary assignment of the coordinates of the measurement points; measurement of the workpiece at these points; and identification of the position coordinates of the workpiece during processing. Measurement of the part at the same points after treatment, it is experimentally proved that the time for planning improvements is reduced by 3–6 times. The technique was tested in the factory by a number of enterprises—suppliers of auto components of KAMAZ Corp.

D. T. Safarov, S. V. Kasyanov, A. G. Kondrashov
Investigation of Parts Thermo-Frictional Treatment Using Special Dynamic Appliances

The results of experimental analysis of the parts thermo-frictional treatment operation processes using dynamic instrument have been presented. The results of mathematic simulation of dynamic processes taking place at parts thermo-frictional treatment have been given. The results of theoretic investigations were proved by the experiment when treating the control part. Special dynamic appliances to increase the quality of parts thermo-frictional treatment were developed. The appliance comprises the table on the elastic suspension. Mathematic simulation of a part thermo-frictional treatment on the dynamic appliance was performed. The results of simulation have been supplemented by an experimental investigation of oscillatory processes. The part dynamic movements at its treatment have been determined.

N. Pokintelitsa, E. Levchenko
Methodics of Quality of Hydroabrasive Waterjet Cutting Machinability Assessment

The occurrence of delamination and value of stratification at drifting by hydroabrasive waterjet are influenced by the number of factors including “unmanageable” and “accidental”. In view of the above, the necessity to develop the method of glass fiber plastic machinability assessment is arising. This method includes not only recommendations about the choice of the technological modes (the “controllable” factors), but also the influence of “unmanageable” factors on the drifting process is also considered for obtaining a required processing quality.

G. Barsukov, T. Zhuravleva, O. Kozhus
Substantiation of Structure and Basic Design Parameters of Devices for Orienting Powered Support Relatively to Face Conveyor in Formation Plane

One of the reasons for the inefficient use of powered support due to the dislocation of the direction of movement of the powered support unit relative to the face conveyor in the formation plane is identified. The substantiation of the structural parameters of the connection of the eye of the cap of pile of the movement mechanism of the linear powered support unit with the eyes of the face conveyor was carried out. The dependence of the angle of rotation of the eye cap of pile of the movement mechanism in the eyes of the face conveyor is determined. The necessity of installing armored powered support unit equipped with rod transfer mechanisms is substantiated in the lower part of the breakage face. The developed design of the movement mechanism of the anchor sections is of the same design as the movement mechanism of the linear powered support unit and differs only by the cap of pile. The cap of pile of the anchor sections has two spaced lugs that are pivotally connected through axes to the eyelets of the face conveyor. The proposed mechanism for moving the anchor sections provides for the directional movement of powered support which significantly increases the efficiency of the complex.

Y. V. Turuk, N. I. Sysoev, B. B. Lugantsev
SPG Simulation of Free Orthogonal Cutting for Cutting Forces Prediction

Metal processing by cutting is a common process. The accuracy and quality of a machined part essentially depend on cutting forces and mechanics of the cutting process. Along with experimental measurements, there are many numerical techniques for cutting forces prediction. The purpose of this paper is evaluating of the Smoothed Particle Galerkin (SPG) method for modeling metal cutting and cutting forces prediction. SPG is a relatively new mesh-free method, and severe material deformations arising in the cutting process can be treated in such a way that mesh distortion is of minor effect. The SPG method leads to no element deletion, and material failure and chip formation are controlled by phenomenological failure criteria. A proposed SPG model was verified and showed a good similarity in modeling chip formation and more correct estimating the chip shape comparing with SPH as illustrated in some orthogonal cutting examples. The chip shape and cutting forces predicted values obtained with the help of this method were compared to SPH. The aim of the proposed approach is reducing high-cost experimental work or at least its amount.

I. S. Boldyrev
Structural Risk Analysis as Basis for Quality Control of Metallurgical Systems

The brief review of the quality control system for complex technical systems is given. A generalizing condition for the analysis and control of safety as the basis for quality control of any complex technical system based on the risk theory has been adopted. The technical risk analysis cannot always adequately evaluate the safety of the structure, so the transition from technical risk to the structural risk of complex technical systems is shown. As an example of such systems, it is proposed to investigate cranes casting bridge type, operating in heavy and superheavy operation modes. Four blocks (subsystems) of the first level of structural risk and ten elements of the second level have been singled out. On the basis of the evolving structural risk theory, its meaningful formulation for complex metallurgical systems is given. A model of structural risk coordinated by goals and tasks has been constructed. The evaluation of structural risk as the probability of catastrophic destruction of a group of objects, metallurgical bridge cranes, will allow one to formulate and analytically determine the parameters of their quality control from the position of safety and reliability.

Yu. A. Izvekov, E. M. Gugina, V. V. Shemetova
Use of Dynamic Programming Method to Design for Optimal Performance of Grinding Cycles

The design of an optimal grinding cycle that provides execution of all requirements of a drawing in terms of precision and quality in the shortest possible time is a complicated scientific and technical task that could be solved with a dynamic programming method (DPM) that is considered to be a method of optimal control theory. This article discusses the main aspects of DPM application for the optimization of short grinding cycles. The application of this method is stipulated with the fact that there is no need to limit a tolerance zone and this method is not sensitive to properties of control model and restrictions. The result is an ability to apply restrictions of precision (accuracy) not only to diametrical errors (inaccuracy) but also to form the deviation of surfaces. The purpose of operations efficiency increase defines the criteria of objective function to provide the shortest possible time of treatment.

P. P. Pereverzev, A. V. Akintseva, M. K. Alsigar
Modeling Relationship Between Different Stages of Cylindrical Grinding Process with Axial Feed in Reversal Zones

Operation efficiency management for cylindrical grinding with axial in-feed (for instance, internal and external grinding) at a numerical control machine (CNC) is performed with an automated adjustment of radial and axial in-feed within a staged cycle depending on the amount of the remaining part of allowance. However, grinding in reverse and non-reverse areas is performed with different cutting modes due to a number of factors: the presence of cylindrical grinding with radial in-feed at penetration stage at the beginning of a working path, necessity of reverse switch of axial in-feed, and the cutout of axial in-feed at penetration and reverse switching stages. As a result, the dynamics of actual radial in-feed and cutting force in all sections of a treated surface is significantly different in terms of grinding methods and value. That is the reason why treatment precision may vary depending on the length of a treated surface. The article describes the standardization processing steps of the scientific method in the reverse zones and shows a functional relationship interaction the actual radial feed, programmed radial feed in axial feed grinding. Also, there are data on how elastic deformations change the axis of the circle at all stages.

P. P. Pereverzev, A. V. Akintseva, M. K. Alsigar
Profile Gear Grinding Temperature Determination

The paper is devoted to solving an important scientific and technical problem of determining the profile gear grinding temperature based on the choice of simple but at the same time adequate solution from the available analytical ones. The initial prerequisite for the paper developing concept is that of a moving heat source, which was originally proposed and investigated by J. C. Jaeger. In engineering applications, the moving heat source is often represented in the form of the moving contact zone between the grinding wheel and the workpiece surface, which forms a three-dimensional or two-dimensional temperature field in the Cartesian coordinate system around itself with and without taking into account the influence of the source length in the direction, which is perpendicular to the direction of the source moving, respectively. There is another possibility to simplify the determination of grinding temperature by choosing a one-dimensional solution of the differential heat conduction equation in which the source moving with the certain velocity is absent and replaced by the time of action of a stationary heat source. This time is equal to the ratio of the contact length to the velocity of its moving. Due to the high speeds of discontinuous gear grinding process, the replacement of the moving source by a stationary one often does not affect the accuracy of determining the grinding temperature in a thin surface layer.

N. V. Lishchenko, V. P. Larshin
Development of Complex of Performance Indicators of a Flexible Abrasive Tool for Assessing the Effectiveness of Application

The results of the development of a complex of operational parameters of a flexible abrasive tool and methods for quality control of grinding bands, grinding paper, etc. are given on performance indicators and quality control of the petal circles in production conditions for performance indicators. Analytical models have been developed to calculate the selected indicators, and their physical meaning has been determined. The developed sets of performance indicators specify the minimum necessary and sufficient number of indicators to assess the properties of a flexible abrasive tool. Application of the developed set of operational parameters of a flexible abrasive tool, determined by uniform methods of quality control of FAT in production conditions, allows using a flexible abrasive tool for its intended purpose economically and efficiently.

N. V. Syreyshchikova, V. V. Batyev
Renovation Repair of Trunk Pipeline While Operation

Main pipelines for oil and gas transportation are among the most expensive and largest facilities operating under the most difficult environmental conditions and requiring a number of activities aimed at their maintenance. In this context, the development of new high-performance pipeline repair technologies is one of the most urgent tasks to ensure their use reliability. The occurrence of new repair methods and improvement of the existing ones, especially the methods making it possible to restore defective sections without stopping the products transportation process, remains strongly sought-for in terms of main pipelines where any forced stop causes significant economic damage.

V. A. Gafarova, N. K. Krioni, A. D. Mingazhev
Development of Advanced Technologies for Secondary Use of Thermal Energy

This article is devoted to the improvement of technological processes at the objects of the oil and gas complex. One of the main methods considered in this paper is the use of HC air coolers. The use of this auxiliary equipment allows one to remove the increased thermal stresses from the main technological units, as well as to increase the overall production capacity. At the same time, the conducted studies are devoted to the use of modernized analogs for HC air coolers. The essence of modernization consists in the use of vertical arrangement of heat exchangers with sections of bending small radius coils. In addition, the layout is implemented in a modular way, which provides increased operational efficiency of this heat exchange solution. In addition, this technical solution makes it possible to reduce the unit costs for heat exchangers servicing, in view of their smaller metal capacity, greater reliability, and ease of use. As a result, the reliability and cost-effectiveness of individual technological operations are increased (in particular for technological operations, in which equipment is used under high pressure and a temperature background).

D. Bylinkin, A. Zaplatyn, R. Karymov
Development of Mathematical Model of Material Removal Calculation for Combined Grinding Process

The article is devoted to the development of a mathematical model of the combined grinding process. Based on the main provisions of the theory of abrasive processing, dependences are developed to calculate the probability of removal of the material at any point of the contact zone taking into account several simultaneous processes of formation. The electrochemical grinding model presented in the article makes it possible to determine the removal of material from the workpiece taking into account the process of anodic dissolution, mechanical cutting, and their combination of the above processes. In the course of the work, equations are obtained that show that the processing of precision surfaces by a grinding wheel by the CBS method in comparison with the processing of blanks in accordance with the traditional algorithm provides higher accuracy and productivity. The complexity of the physical processes of surface formation connected with a large number of technological factors, with the help of which the parameters of this process can be changed, is shown. The model takes into account the peculiarities of the stochastic nature of the abrasive processing process and the interaction of additional physical processes and technological factors. During the development of the model, graphical dependences of the gap size for any point of the contact zone and the total gap of the part with the circle from the process parameters were obtained. An example of the calculation of the electrochemical removal of material from the unit area of the developed model is given.

S. Bratan, B. Bogutsky, S. Roshchupkin
Method for Compensation of Radius and Shape of Spherical Probe When Measuring Complex Surfaces with CMMs

Measurement practice on coordinate measuring machines showed that the real measurement accuracy is usually much higher than indicated in the technical documentation. The overall error in measuring the geometry consists of the errors in determining the point of contact on the surface of the part, compensation for deviations in the location of the base surfaces, and errors in calculating the surface parameters. The error in determining the touch point of the probe and the part is due to the difference in direction between the normals to the nominal and real surfaces. Therefore, the calculation becomes necessary to compensate the radius of the touch probe. A simple compensation method calculates only the normal to the nominal surface of the workpiece. More advanced methods take into account the coordinates of neighboring touch points and calculate equidistant surfaces. The article proposes an iterative method of compensating the radius of the probe by successively refining the coordinates of the point of tangency with respect to the nominal surface. In this method, the angle between the normals to the nominal and real surfaces at each measured point is minimized. Comparison of the results of compensation of the probe radius by the developed method with the standard method confirmed the high efficiency. The article provides an example of calculating the compensation of the probe radius for the turbine blade of the compressor, which showed a decrease in the measurement error by 23–29%. The application of the new method is useful when there is a small number of measured points and their location on the complex uneven surface.

F. V. Grechnikov, A. V. Kochetkov, O. V. Zakharov
Magnetic Inspection for Assessing the Uniformity of Flange Joints Bolt Tightening

Flange joints refer to the most widespread detachable joints used in various industries. Such joints should be strong, durable, and leak proof. Compliance with these requirements depends largely on the uniformity of bolt tightening. In flange joints, it is necessary to provide that all bolts (pins) are tightened with equal force. Nonuniformity of bolt tightening could lead to different negative consequences, for example, to the lack of parts alignment, irregular gasket compression and as a result leaking of the product, misalignment of connected details, the origination of fastening details plastic deformations, and even breakage of bolts or pins. That is why controlling steel pins and bolts tightening force is very important for the provision of joint reliability and not only during assembly and installation of units and details of any other equipment but also during its operation. The present article is devoted to studying and testing of one of the modern and universal methods of bolt (pin) tightening force control—magnetic inspection based on structure-sensitive magnetic parameter control—remaining magnetic induction of the metal. The aim of present studies is to test the metal mechanical stress indicator IH-01m of a scanning type used at real facilities for measuring pin tightening force during operation.

R. B. Tukaeva, A. A. Prokhorov, O. Yu. Miniakhmetov
Research of Temperature Phenomena During Machining Surface Plastic Deformation of Detail

Surface plastic deformation of rollers is widely used to ensure the specified quality parameters of the surface layer of machine parts during their processing. Thermal processes during the processing of details by superficial plastic deformation of rollers can significantly influence the quality of the surface layer. In the article, the issues of identification regularities of the influence of processing modes and design parameters of deforming rollers at surface plastic deformation of a detail on the formation of temperature in the contact area between a deforming roller and a processed surface are considered. The known literature references do not provide uniform data in terms of applied calculation methods, therefore, it makes it difficult to conduct a comprehensive analysis of obtained dependencies and limits the ability to compare different options. The mathematical model is based on studying the process of a surface plastic deformation of calculating temperature in the contact region. Based on the research of resulting mathematical model, it is established that the temperature formed in the contact zone is much smaller than the permissible one at which there can be a change in the quality parameters of the surface layer.

Ya. N. Oteny, E. V. Morozova, V. F. Kazak
Neural Network Modeling and Prediction of Adhesion of Coatings Applied by Wire Tool

The article deals with the formation of adhesion bonds in the process of applying coatings to machine building products by the method of cladding by a flexible tool. The main points of the mathematical model for determining the adhesion of applied coatings are shown. The calculation in the model is based on the use of the coefficient of relative strength for the particles adhesion of the coating material to the workpiece, the contact temperature of the particles with the base material during their interaction, and the energy of thermal activation of the surface as a result of the chemical reaction considering the energy of mechanical activation. The dataset of the coefficient of relative strength for the adhesion is given for varying the circumferential velocity of the tool, the diameter, and the length of the wires from which the flexible tool is assembled. The modeling of the dependences of the relative strength coefficient is considered as an approximation problem using artificial neural networks. The input data are the technological and structural parameters of the cladding. For modeling, a two-layer feed-forward network is used. For a problem of partitioning input parameters into regions of permissible or unacceptable from the point of view of providing a given coefficient of relative strength, a similar neural network with an output layer with a softmax output neuron is used. The use of two approaches makes it possible to accelerate the design of the cladding operation while increasing the reliability of the decisions made.

A. V. Zotov, D. A. Rastorguev, O. I. Drachev
Mechanism for Flow Forming of Cylindrical Workpiece

This article gives a brief overview of the process of flow forming and technical equipment used for its effectuation. Also, the authors noted the main drawback of the existing technology of flow forming, which is evident in the jamming and slipping of deforming rollers. In the paper, we propose a construction of the mechanism, executed in the form of a closed differential gear, which makes it possible to avoid such drawbacks. The main distinguishing feature of this mechanism is that the deforming rollers have a forced rotation from an actuator. The authors obtained an analytical dependence that makes possible to adjust the kinematic chain of the described mechanism based on the absence slippage of the deforming rollers. The mechanism is adjusted by changing the gear ratio of the additional kinematic chain, which includes the regulating and reversing unit for the rotation of the shafts. The regulating and reversing unit can be made in any of the structural designs which allow eliminating slippage of the rollers. Practical recommendations for setting up the mechanism before operation are given. The mechanism can be used both in the stationary production rooms and in the mobile technological complexes in the field.

A. A. Udalov, S. V. Parshin, A. V. Udalov
Study on Tribological Characteristics of High Entropy High-Speed Steels in Conditions of Dry Friction on Structural Steel

The connection between the entropy of HSS grades and their frictional properties and elastic strength characteristics of surface layers at the microlevel was experimentally confirmed. It was established that the best friction characteristics are connected with a high level of entropy, which apparently can be explained by the peculiarities of forming the third body (build-up layer) and its composition. The growth process of the third body for high entropy HSS flows with a greater speed than its destruction, and the obtained thickness of the third body contributes to the alienation of friction surfaces reducing the strength of adhesive joints and the coefficient of friction. These properties become apparent under conditions when the value of thermomechanical activating effects in the friction zone is of an adequate level. It was established that build-up layers on specimens of high entropy HSS have a greater stability due to their high hardness and low elasticity of surface layers. The authors proposed the process of build-up layer formation during friction for HSS having various entropy levels characterized in the first approximation by the two quantitative indicators: the maximum possible value of build-up layer thickness under specified conditions and the relative rate of build-up layer formation versus destruction. It was assumed that the calculation of entropy values as structurally sensitive characteristics of the tool materials may be used for a priori prediction of the tribological properties of existing and newly developed grades of HSS.

A. A. Ryzhkin, E. V. Fominoff, C. G. Shuchev
Assurance of Quality Characteristics for Electric Weld Pipe Mill Roll

The paper is dedicated to the assurance of precise machine parts quality characteristics. The emphasis is put on the importance of taking into account the phenomena of technological inheritance and mutual influence of parts quality characteristics in order to estimate the expected characteristic values more precisely. The influence of the initial microhardness of the workpiece surface on the resulting roughness is considered and the dependence between the roughness height parameters and the initial microhardness of the workpiece surface and the parameters of the machining condition for the finish turning and diamond burnishing is obtained. The dependence could be used in the computer model of quality characteristics transformation during the workpiece machining for development of the technological process considering the phenomena of technological inheritance and mutual influence that will ensure directed creation of required characteristics.

V. V. Maretskaya, A. V. Zaytsev
Correlation and Regression Method of Centrifugal Pump Geometry Optimization

Correlation and regression analysis is the effective means to study the narrowness and analytical relationships of the factors to be analyzed. It can be applied in technics as a result of gathering and processing of operational data or results of tests of already existing samples of machinery, for example, for centrifugal pumps upon hydraulic tests. This article covers the procedure of correlation and regression analysis of centrifugal pump head and efficiency dependencies on its impeller geometry in meridional and circumferential planes. The purpose of the analysis is to optimize the impeller geometry in order to achieve the maximum pump head ratio and efficiency. This article provides a detailed description of the proposed optimization method of the design. Geometric factors more significantly effecting the energy parameters of the pump are included in the mathematical models connecting the energy parameters of the centrifugal pump with the relative geometric dimensions of the impeller. Based on the obtained models, optimization of the impeller geometry is performed by adjusting the absolute dimensions of the impeller interblade channels to the values corresponding to the optimum ones determined by correlation and regression analysis. This approach allows modification of existing equipment based on the mathematical processing of empirical data appearing only after the beginning of operation. The correlation and regression method of design optimization is one of the few means for efficient use of operational data not only in the field of centrifugal pumps but also in other hydraulic machines and devices as well. This method is informative, does not require intensive experimental studies, and provides for a modification of the equipment with the minimum material and financial expenses.

I. Katalazhnova
Optimization of Flows in Jet-Film Contact Devices

Within the scope of works on increasing the efficiency of heat and mass transfer processes, a design of an apparatus with a new jet-film contact device is proposed. The calculations were conducted to research the heat interaction of the surfaces of the new contact device and the inner wall of the apparatus with different environment (air, carbon dioxide and water vapor), the contact of the environment with the surface of the inner wall of the apparatus, with the surface of the vertical baffle plate, with the free surface of the outer stage, and with the free surface of the inner stage of the jet-film contact device were considered. It is shown that the heat transfer coefficient at a high flow velocity (20 m/s) is different for air, carbon dioxide, and water vapor. It is proved that the physical properties of the environment differing in the Prandtl number determine the dependence of the Nusselt number on the Reynolds number. It is found out that it is efficient to direct the maximum number of flows to the surfaces of the inner wall of the apparatus and the outer stage of the contact device, where the heat and mass transfer process is the most intensive. Criteria dependencies for the studied surfaces and environments were obtained. The studied dependencies show high values of the Nusselt number which suggests high efficiency of the contact device.

A. V. Dmitriev, E. I. Salakhova, O. S. Dmitrieva
Multiphysics Simulation of Electromagnetic Forming of Aluminum Alloy Tubes

This paper is devoted to the study of coupled electromagnetic, mechanical, and heat transfer processes at electromagnetic forming of tubes. A multiphysics mathematical model of coupled, high-speed electrical, magnetic, mechanical, and heat transfer processes in the system “Installation-Coil-Workpiece” taking into account the characteristics of the technological system is developed. Numerical simulation of electromagnetic forming was performed by a finite element method within the 2D axisymmetric approximation. The effect of the main process parameters and modeling technique on electromagnetic forming of aluminum alloy tubes are investigated.

V. M. Volgin, V. D. Kukhar, A. E. Kireeva
Predictive Modeling of Scribing Brittle Material Using Diamond Tool with Improved Geometry

This paper discusses the predictive modeling of a scribing process. The diamond tool geometry is important for this process. As a prototype for the diamond tool, a four-sided pyramid is taken. Some minor changes are made in its geometry in purpose to make the modified tools. The tool geometry is a factor which affects greatly the quality of a final product, its forming, and overall efficiency of the scribing process. Scribing a brittle sheet with the modified tool is studied via parametric finite element modeling (FEM) with aid of the ANSYS software package for computer-aided engineering. The heterogeneous mesh is generated using solid finite elements with a quadratic form function. To obtain more precise simulation and decrease singular effect under force loading conditions, the contact elements and increased density of knots near the tooltip are added in this mesh. The modified variants of the tools are developed to provide a necessary groove quality on a brittle material surface regardless of movement direction. Finally, the algorithm and the corresponding program module for the parametric solution have been created using internal ANSYS APDL programming language. The computation results sufficiently agree with the experimental data obtained in this work and earlier. The calculated stress intensity in the sheet along the normal direction to the surface has large value up to 15 μm from cutting tool tip and decreases more sharply on the surface than in the cross section. So, the approach presented in this paper helps to understand the cutting process and improve machining technology of brittle materials.

A. I. Ogorodnikov, Yu. N. Zhukov
Packing Compaction Algorithm for Rectangular Cutting and Orthogonal Packing Problems

The rectangular cutting and orthogonal packing problems which have many practical applications in industry and engineering are considered. Increasing the density of placement schemes leads to reducing the material usage in solving the rectangular cutting problems and reducing the unused resources at solving the orthogonal packing problems. This article contains the description of the developed packing compaction algorithm and its investigation. This algorithm uses six object selection rules, which select objects from a container for deleting and subsequent reallocation of them into freed spaces of the container. The packing compaction algorithm iteratively applies a one-pass heuristic algorithm which finds the best placement of the deleted objects in order to increase the density of the result packing. The effectiveness of the application of the proposed algorithm is investigated on the standard two-dimensional strip packing problems which are the rectangular cutting problems with only one container of a fixed width and an infinite length. Based on the test results, the effective sequence of application of the proposed rules used as the part of the packing algorithm was determined. The packing compaction algorithm is implemented in a general form which makes it possible for application in the rectangular cutting and orthogonal packing problems of arbitrary dimension.

V. A. Chekanin, A. V. Chekanin
Predictive Modeling of Design Innovative Solutions on Tooling Configurations at High-Tech Manufacturing Companies

The article considers the method for making up a set of predictive models for design innovative solutions forming and selection in the area of the high-tech production tools configuration. The model set structuring is represented by a system of multilayer graph models combining input information forming; generation of new product properties; idea synthesis and analysis; configuration of forming operation tooling; forming of a set of technical, economic, and manufacturing criteria. The set of possible shaping systems is a function of the set of traversal routes, which in their turn are generated by consecutive inter-layer transitions from input edges to edges describing the optimal tooling configurations by means of targeted structural and parametric synthesis. The authors developed the mathematical model for forming a set of configurations for the production operation tooling. The problem of the optimum innovative solution selection is solved by means of the Boolean algorithm for linear programming. The research practical tests were performed by means of the technological synthesis problem solution for the multiaxial laser cutting machine.

S. Lukina, M. Kosov, I. Tolkacheva
Method of Energy Efficiency Increase of Low Power Radial Impeller Micromachines

The article is dedicated to the analysis of possibilities of hydrodynamically feasible velocity and pressure field formation in the impeller of low power radial impeller micromachines, up to 50 W, by means of flow control by methods of the border layer theory described in Schlichting’s papers. The purpose of the control is to reduce the extent of energetically unfavorable factors reducing the machine’s specific power. These factors include flow separation zones, secondary currents, and corner vortexes, “slippage” at the output of the impeller interblade channels. It is stated that the basic methods of flow structure control include blowing, suction, and turbulence formation, in particular, turbulence formation of local different energy flow areas existing in channels of radial impeller machines. The article covers the layout of such areas and ways of possible exchange between them. Besides, the working energy efficiency decrease of interblade channel slanted cut of machine impellers is analyzed. The method of turbulence formation is recognized as the most acceptable method of control of flow structure for micromachines. The experimental part of the study was to check the efficiency of flow turbulence formation in the impeller of a radial impeller machine in order to increase its specific power. Comparative hydraulic tests of the same centrifugal micropump with flow turbulence formation in the impeller and without turbulence formation were performed. A metal mesh with a free area ratio of 0.51 fixed on periphery of the impeller was used as a turbulator. The tests showed that installation of mesh increases specific power of the pump featured by head coefficient value, by 28.4%. This allows reducing the diameter of machine impeller by 5.3% while retaining the original power.

A. Bobkov
Separation Efficiency of the Heat–Mass Transfer Apparatuses with Jet-Film Contact Devices

The drop entrainment of condensed moisture by gas or vapor is often observed during operation of different electric power units and heat–mass transfer apparatuses. This moisture gets into the vapor flow at a fragmentation of liquid during the process of bubbling, as well as breakup of jets and disruption of the vapor bubbles’ skin. The use of heat–mass transfer contact devices with great separation ability at high loads both of the gas and liquid phases is very promising as it eliminates the need for additional separating devices. A comparative analysis of various design and duty parameters of the operation of jet-film contact devices shows that the greatest separation efficiency corresponds to the contact elements with additionally installed bottom boards. The studies revealed that the impact of the scale effect on the separation efficiency can be neglected, if the diameters of dispersed particles do not exceed 5 μm. The conducted studies on determination of separation efficiency of aerosol particles in the apparatuses with jet-film contact devices will allow correcting the known mathematical descriptions of turbulent settling of dispersed particles in order to use them in calculations for engineering design of new contact devices.

A. V. Dmitriev, I. N. Madyshev, O. S. Dmitrieva
Methodology for Automated Design of Optimum Cylindrical Broach Structures Developed by Total of Criteria

The broach is a metal-consuming and complex tool in terms of its structure and manufacture. Its economic feasibility is justified at the optimum structure design, choice of reasonable cutting modes, quality manufacture and proper operation. The authors considered a methodology for the automated design of optimum cylindrical broach structures. The methodology is based upon the building and solution of a linear optimization model in MS Excel. Upon modelling, the broach structure is represented by a total of structural and geometrical parameters. The following properties were chosen as the optimization criteria: stability, strength and stiffness of a working section, and its length, performance and self-cost of broaching. The selected criteria formed a system of target functions. The feasible region is determined by a system of structural, technological and operating limits for the broach parameters. The shaped mathematical model allows for the calculation of optimum values of the structural and geometrical parameters of cylindrical broaches with single and group cutting patterns and chooses the cutting modes.

S. Lukina, M. Krutyakova
Forming and Selection Technique for Optimal Configuration of Form-Shaping System for Multiple-Axis Machining

An early project stage is the most important one, as the success of the form-shaping systems for multiple-axis machines project itself highly depends on the right choice of arrangement. As a rule, during the machine tool construction, the main things are experience, existing constructions of analogue machines and intuition. The task of choosing the most appropriate variant of the form-shaping systems for multiple-axis machines construction is very complicated and dubious, requiring the consideration of numerous constructive and technological restrictions, and to solve it, one must develop certain means of formalized project decision-making. The aim of this paper is the formation of graph models that allow us to formalize the interrelationships of the requirements for the multi-axis machining operation with the performance characteristics of a multi-axis machining system. This paper presents a technique of forming and selection of optimal configuration of the form-shaping systems (for multiple-axis machines) based on the integrity of graph models, analytical representations and objective functions.

I. Manaenkov, V. Makarov
Rolling of Refractory Metals on Four-Roll Passes Rolling Mills

Drop and rotary forgings of molybdenum or tungsten rods and wire rods requires a great number of operations accompanied by significant losses in expensive metals and low quality of half-finished products. Therefore, it is of great importance to develop new effective methods as well as the appropriate equipment for high-quality treatment of molybdenum, tungsten, and their alloys. The paper presents one of the methods—multi-pass rolling with multi-sided reduction of powder sintered blocks. Intensive three- or four-sided reduction of the block leads to a favorable strain-deformation conditions at the point of the applied deformation allowing to obtain the appropriate scheme of that state of the material. As a result, the plasticity of the rolled material increases and its cross-flowing slows down. High plasticity of the material allows to increase the degree of multi-sided reduction of rods or stocks and, therefore, to reduce the total number of treatment operations, to reduce the losses of metals, and to improve the quality of rolled products and their mechanical characteristics. Slowing down the cross-flowing of the metal during multi-sided reduction of its blocks in the process of rolling allows for a more effective deformation, low energy consumption, and cut number of block passes. Thus, four-sided reduction gives the most favorable scheme of the strain-deformation state of the material under the condition of multi-sided, nonuniform reduction of the blocks in the process of rolling.

L. A. Barkov, M. N. Samodurova, D. P. Galkina
Dependences of Blanks Density from Pressing Force and Packing Density of Molybdenum and Tungsten Powders

The paper presents an analysis of known theoretical dependences of the density from the force made by native and foreign scientists and experimental results received by scientists of the South Ural State University in the industry conditions with the powders of molybdenum and tungsten. The investigations were carried out using pure tungsten powders, pure molybdenum powders, and powders of molybdenum grades of Mo–Th, Mo–Y, and Mo–La. The parameters of the powders studied (bulk density, average grain size of the powder, and impurity content for each batch of powder), as well as parameters of the process of pressing the blanks (dimensions of blanks, pressing pressure, pressing force, and density of blanks after pressing) are given. As an industrial tool, an industrial hydraulic press was used, as well as a demountable mold of the construction of the authors of the article. On the basis of the data obtained, the dependences of the density on the pressing forces of powder blanks from various tungsten and molybdenum grades for industrial use have been compiled and tested.

L. A. Barkov, M. N. Samodurova, Yu. S. Latfulina
Experimental Installation for Analysing the Dynamics of Cutting Forces and Vibrations at High Frequencies of Machine Spindle Rotation

The article describes the experimental installation developed on the basis of Hermle C22 processing centre. The information and measuring system for data processing and analysis has been developed. The paper discloses the mechanism for obtaining a complete set of data on dynamic processes flowing in the elastic system of the installation given. The recommendations on positioning strain gauges and vibration acceleration sensors are outlined. A specific application area for the experimental installation has been proposed.

M. N. Krasnova, S. V. Safonov, D. M. Chernykh
System Approach and Multivariance of Screw Surface Profiling

The article demonstrates the urgency of the problem of screw surface profiling and the drawbacks of the existing profiling methods. It justifies the applicability of the system approach to the problem of screw surface profiling. The main types of structural elements, types, and the purpose of their parameters are identified on the basis of the system approach. This allowed one to identify the reasons for the emerging multivariance of solving the profiling problems, which is determined both by the interrelationship of structural elements and the variability by their initial parameters, and by the need to ensure conditions for a correct shaping of screw surfaces. The article identifies the possible types of screw surface profiling problems which are called tool, control, adjustment, and combined. It shows the role of each problem in practical use. The classification of profiling problems allows one to predict the development of profiling methods and reflects the development of the theory of screw surface shaping.

S. D. Smetanin, V. G. Shalamov
Practice of Dimensional Modeling of Assembly Operations Using Static Compensators

The paper presents a process of dimensional couplings modeling in assembly operations using single-circuit graph models, describing the mechanism of individual components mating. The method of incomplete interchangeability is used for the description as being the most common in the current manufacturing conditions. The authors consider the calculations based on the defined mathematical model, which can be applied to single-circuit and multi-circuit dimensional schemes in various manufacturing conditions. For mass production, an algorithm is proposed to determine the scattered field of upper and lower limits of adjusting gaskets. The calculation method is demonstrated using specific examples describing extreme events of interaction between the dimension chains of parts in the assembling department. With that, the nominal controller link is viewed as having a positive reduction ratio.

M. G. Galkin, A. S. Smagin
Computer-Aided Algorithm for Nonlinear Optimization of Pre-machining Using Measuring Instrument

In a computer-aided multivariant design of processes, an important problem consists in optimizing the machining parameters for making holes in solid workpieces. When solving this problem, there arise such problems as choosing solution methods and optimization criteria as well as determining the scope of acceptable solutions. For instance, if using a linear programming algorithm, one has to simplify their solutions which are acceptable if computational capacities are limited. Due to the fact that, when describing an optimal metal cutting process with different machining methods, both the target function and the system of constraints are nonlinear; it is, therefore, obvious that the most acceptable computational algorithm consists in solving a nonlinear programming problem based on the method of Lagrange multipliers. The paper dwells upon automating this particular problem for making holes in a solid material when a measuring tool is used for machining.

M. G. Galkin, A. S. Smagin
Verification of Finite Element Model of Deformation of Laboratory Sample for Mechanical Tests by Method of Digital Images Correlation

The paper deals with the experimental-calculated analysis of the deformed state of a prismatic-type sample for mechanical laboratory tests, which is designed to evaluate the strength of a material under a biaxial stress state. A description of the deformation scheme of this sample is given. The distribution of deformation fields of the prismatic sample surface studied is obtained by processing the speckle images of the onboard experiment by the method of correlation of digital images in the Vic-3D system, at the stage of elastic deformation. Their comparison with the results of numerical simulation by the finite element method at control points of the surface of the deformed sample is performed. The discrepancy between the results of the full-scale experiment and the given numerical simulation at the control points did not exceed 14%. Conclusions are formulated for the subsequent use of the results obtained.

E. V. Zenkov, L. B. Tsvik
Impact Impulse Research During Ice Navigation with Computer Modeling

The research of the strength of vessels at navigating in Arctic shelf area in compacted and brash ice is a significant issue from this point to ensure the hull strength when it hits the ice. Using the design and engineering analysis of automated systems we can improve the quality and efficiency of the designed product and its elements by increasing the number of options under consideration of design decisions and more detailed research. In addition, it provides for a reduction in the amount and labor intensity of technological operations during production. Using specialized software, the study of the ice hitting the hull was conducted. The study showed a pretty good convergence of the experimental and theoretical data, and the performance of the hull stresses resulting from the research is more informative and detailed, the results were described in materials of the previous conference. Within the current study, the modeling features are being continued to be researched in terms of the hit trajectory and ice characteristics.

D. Slavgorodskaya, V. Bugaev
Estimation of Influence Character of Installation Loads on Degree of Corrosive Wear of Column Apparatus

The rectification columns of oil and gas processing and petrochemical enterprises play a leading role in the production of intermediate and finished products. During their operation, column apparatuses are exposed to the operating load as well as to the corrosive working environment. All the above factors cause the development of the degradation processes in metal and its premature wear. Therefore, there is a problem of increasing the service life of the equipment, taking into account the factors that affect the operational properties of the equipment at all stages of its life cycle. The impact of the typical for such a stage as the production of installation works on the installation of column equipment in the design position has not been sufficiently studied. This implies the task of verifying the hypothesis of the effect of installation loads on the geometric parameters of the columns after a certain period of operation of the equipment. In this paper, we investigate the relationship between the maximum loads on the column apparatus casing that arise during the installation of equipment and the areas of increased corrosive wear revealed by measuring the wall thickness during technical diagnostics. Based on the research results, certain measures have been developed to eliminate or reduce the negative impact of installation loads.

Z. R. Mukhametzyanov, A. V. Rubtsov, A. S. Valiev
Radiation Individual Control Method in Engineering

This paper reviews a problem of dose control while using the sources of gamma and X-ray radiation in the engineering industry and other enterprises using the nondestructive testing devices. Distinctive features of the used resources are the high energy and intensity of used radiation at the short time of the delivering testing. The research is devoted to the problems of the high energies control. The influence of radiation used in the industrial purposes was studied before, but nowadays, the types of radiation resource have other parameters. This investigation is devoted to the radiation sources of high-energy radiation. In this case, low-energy effects were playing small influence at this energy level, but others effects grew and started playing a significant role. The most important changes have been described in the paper. Nowadays, the application of radiation control system allows conducting the complex monitoring control with wide range energy with providing security.

G. S. Morokina, Zagdzusem Mungunkhulug

Surface Transport and Technological Machines

Frontmatter
Technology of Creation of Three-Dimensional Model of Tractor Transmission in Program Package “Universal Mechanism”

This paper describes the technology of creating the model of drivetrain of the tracked agricultural tractor Chetra 6C-315. Two-dimensional dynamic models do not provide an accurate representation of the whole complex of active and reactive forces acting on moving masses. Three-dimensional models provide much more opportunities for describing loading processes. The model was created in the program package “Universal mechanism” on the base of the kinematic scheme of transmission of tractor CHETRA 6C-315. The model consists of three main types of elements: “rotational joint”, “gearing”, and “planetary gear”. A program package includes a mathematical description of each element and the user has to specify only elements properties. In a planetary gear model for defining sun gear, crown gear, and carrier, joint with six degrees of freedom was used, and the connection between satellite and carrier is described with the rotational joint. As the result of full description describing of all elements of the tractor transmission, its three-dimensional model was obtained. The model takes into account reactive forces and moments from the casing and frame elements, and also from the engine. The model allows specifying a character of engine torque changing during the research. The characteristic of the engine torque is obtained from an indicator diagram beforehand. The analysis of results allows to find transmission areas with the highest dynamic load and to propose design ways for decreasing this load.

V. V. Shekhovtsov, N. S. Sokolov-Dobrev, M. V. Lyashenko
Elastic Toroidal Wheel Rolling with Side Slip

The toroidal convex of the treadmill wheel increases the rolling resistance force and its wear rate which usually takes place only at small longitudinal forces in the contact zone. However, there are practically no data of the influence of this structural parameter of the wheel on its force kinematic characteristics under the straight rolling with slip. This paper is devoted to this problem. To solve this problem and assuming that the contact area is close to ellipse while the normal pressure is distributed under the parabolic law, we get the equations determining the lateral force, the cornering moment in the contact zone, the friction loss of different toroidality wheels in the function of a slip side angle, and longitudinal tangential force acting in the contact zone.

T. A. Balabina, Yu. I. Brovkina, A. N. Mamaev
To the Calculation of the Coefficient of Stock of the Clutch

The engine torque is transmitted to the drive wheels of a vehicle through the clutch and transmission. Friction clutches of various designs are the most useful in cars. The reliability and efficiency of torque transmission is determined by the reserve coefficient of clutch. Conventional analytical determination of the magnitude of this coefficient is a calculation based on design parameters of the clutch, and it has a constant value. But the two-mass dynamic model of a car shows that this magnitude cannot be of a constant value. Using this dynamic model, one can determine the magnitude of the reserve coefficient of clutch. This takes into account the technical, constructive characteristics of a vehicle, the gear transmission ratios and driving conditions. Calculated on the basis of the moment of resistance to a vehicle’s movement, the reserve coefficient of clutch will increase its traction parameters.

K. T. Mambetalin
Efficiency of Application Self-blocked Cross Axle Screwball Differential at Car 4 × 4 Movement on Not Deformable Base Surface

The variety of road conditions and factors depending both on the condition of the roadbed and on the weather conditions that determine the conditions of the car’s motion is considered, it is shown that this manifold requires the use of differentials with variable locking ratio, the mathematical problem of optimizing the distribution of torques during the vehicle’s motion is solved with a solid support surface. The obtained regularity shows that the ratio of the torque applied to the wheel to the total torque must be proportional to the ratio of the mass per wheel to the total mass of the car. As an example of such a differential, a self-locking screwball differential was considered, road tests were conducted and experimentally confirmed the efficiency of its application both in terms of optimal power distribution and maintaining the blocking ratio in the most optimal range, and in terms of fuel efficiency.

A. A. Shelepov, D. I. Istomin, E. E. Rikhter
Influence of Uneven Braking of Running Wheels on Stress–Strain State of Crane Metal Structure

The analysis of the influence of the crane braking process on the stress–strain state of the elements of the metal structure is carried out. A mathematical model of the formation of external loads with uneven braking forces on running wheels, and the results of calculating the stress–strain state of the elements of the metal structure of the gantry crane in the Mathcad environment are given. Based on the results of a mathematical analysis of the obtained results, the permissible magnitude of the unevenness of the braking forces is determined. The dependences of the stresses in the most loaded node of the metal structure are obtained depending on the unevenness of the braking forces and the length of the crane span.

S. V. Streltsov, V. A. Ryzhikov
Lifting Mechanism with Ribbon Brake

The scheme of a typical lifting mechanism of the load lifting machine is considered. Its disadvantage due to the placement of the brake pulley on the coupling half located on the high-speed shaft of the reducer is indicated. This determines the rationality of installing the brake directly on the working mechanism of the lifting machine mechanism. The installation of the shoe brake directly on the working element is irrational for design reasons. Therefore, it is suggested to use a ribbon brake. The main drawback of ribbon brakes is the impossibility of predicting failures, caused by the single-element steel tape which is the brake actuating element. Therefore, it was proposed to use as polyurethane ribbon reinforced with steel multi-wire ropes, which acts as an actuating element of the brake. The theoretical foundations of a ribbon brake design are considered and the main design dependencies that can be used in this case are given. The known schemes of ribbon brakes are listed, and it is suggested to use a differential ribbon brake in the lifting mechanism, in which the ends of the ribbon are attached directly to the brake lever on opposite sides of the axis of its rotation. The design scheme of a differential ribbon brake is given and conditions which should be fulfilled at its designing are given. The design of the crane lifting mechanism equipped with a differential ribbon brake installed directly on the cargo drum is presented. The construction of the differential ribbon brake is given. The fastening of the ribbon ends to the axes of the lever is proposed to be carried out with the help of wedge clamps. The brake was calculated with the use of a specially designed computer program.

P. V. Vitchuk, V. Yu. Antsev, A. A. Obozov
Increasing Engine Power by Applying Water Injection

Currently, mobile technological machines and tractor units are mainly equipped with internal combustion engines. Increase in productivity and fuel efficiency of tractor units determine the effectiveness of mechanized production processes in the national economy of the country. As a result of the analysis of literature sources, it was established that one of the promising ways to improve the fuel economy of internal combustion engines is the use of water injection into the intake manifold. The paper presents the results of research on the effect of water injection on increasing engine power and improving its fuel economy. As a result of mathematical modeling, it was established that at the nominal operating mode of the diesel engine 4F 11/12.5 (D-240), the introduction of 30% water into the fuel–air mixture allows to increase the effective power on 10.69 kW or 19.38% (from 55.15 to 65.84 kW). The results of the experimental verification showed an increase in the effective power in a similar mode to 65.99 kW (by 19.59%). Thus, the discrepancy is 0.25–0.50%. The error in calculating the average indicator pressure is 3.95%, which indicates the acceptability for practical purposes of calculating the parameters of the indicator diagram of a diesel engine 4F 11/12.5 (D-240) when using water injection. In the latter case, the relative savings of diesel fuel reaches 36 g/(kW h).

A. Startcev, S. Romanov, O. Vagina
Experimental and Numerical Investigation of Influence of Hydrogen Addition to Hydrocarbon Fuel on Wankel Rotary Engine Performance

Recently, hydrogen has been considered as an alternative for conventional fuels which is used for a transportation sector. The Wankel rotary engine is more adaptable for running on hydrogen fuels than traditional reciprocating engines possessing lower preignition and backfire probability. Experimental and numerical data are presented for the Wankel rotary engine performance on hydrogen blends with hydrocarbon fuel. For the experimental study of the hydrogen addition effect on the engine performance, the Wankel engine test bench VAZ-311 (Russia) was used. The hydrogen and gasoline supply were carried out by injectors mounted in the Wankel rotary engine inlet manifold. The experiments showed that a 5% hydrogen mass fraction in the fuel mixture increases peak pressure in the Wankel rotary engine combustion chamber for partial loads. For the theoretical study, a numerical model of the flame propagation in the Wankel rotary engine combustion chamber was developed. Numerical research revealed the possibility of a complete air–fuel mixture combustion due to hydrogen addition for a number of operating conditions.

E. M. Itkis, E. A. Fedyanov, Y. V. Levin
Influence of Water Injection on Performance of Diesel Engine

The article presents the results of research to improve the fuel efficiency of the engine 4F 11/12.5 (D-240) using water injection. The relevance of the use of water (water vapor condensate) as an additive to hydrocarbon fuel is shown, which contributes to the increase in power and fuel efficiency in the operation of the internal combustion engine. It was experimentally established that the greatest increase in the effective power of a diesel engine 4F 11/12.5 (D-240) is observed when water is supplied in a volume equal to 27–32% of the volume of the cyclic supply of diesel fuel. It has been experimentally established that with an increase in the volume of supplied water, the temperature of the exhaust gases decreases, with an average intensity of about 1 °C per 1% of the water supply. The greatest decrease in the temperature of the exhaust gases was noted at the maximum torque regime. The results of the studies showed a steady increase in the indicator pressure by an average of 18–22%. A decrease in the rigidity of the operation of the investigated engine is achieved, which is explained by a decrease in the rate of change in the indicator pressure (on average by 5–15%), in comparison with work on diesel fuel.

A. Startcev, S. Romanov, G. Romanova
Synthesis of Main Parameters and Experimental Approbation of Test Bench for Study of Working Processes of Intermediate Belt Conveyor Drive

The article considers the state of the study of closed traction circuits used as intermediate drives of main belt conveyors, which showed insufficient experimental investigation of continuous transport vehicles. This circumstance leads to the expediency of developing a test bench for investigating the effect of the intermediate belt drive construction on its working processes. Possible emerging typical defects of belt conveyors, as well as methods for eliminating negative consequences arising during the installation and operation of the machine, are described. On the basis of the resulted defects and operating influences the mathematical model for an estimation of level of the decisions put in design on possible defects of installation and operation of the conveyor belt, approved on the created stand is offered. The procedure for designing a bench to investigate the working processes of an intermediate belt drive of a belt conveyor as well as the manufacturing, assembly, and installation process followed by adjustment are described.

K. A. Goncharov, A. V. Grishin
Theoretical Methods for Precision Increment of Earthwork Made by Power Shovel Actuator

Single-bucket shovels take their place in earth working due to their flexibility, universality, and possibility of their usage in the solution of various building problems. Strict demands for earth-working accuracy are stated in different standards and laws, such as Russia’s SNiP (Stroitel’nye normy i pravila—building norms and rules). Such rules allow soil shortage of not more than 0.05 m while making earthworks. Possible biases of the shovel’s cutting-edge trajectory may be caused by kinematical and dynamical factors. By means of mathematical modeling, possible biases is obtained. It is caused by technological errors of the links of kinematical chain, movement biases of hydraulic cylinders rods, and temperature expansion of machine parts. The sum of such biases exceeds the amount of 0.05 m stated by SNiP. When a mathematical model of the ear working process is developed with dynamical characteristics, it shows additional biases of the shovel’s cutting-edge trajectory. Based on the foregoing, it seems difficult to make earth working of appropriate accuracy. The solution of this problem is developed. It is offered to use a new method to introduce adjustments to control system of power shovel, which is based on moving average. The research held shows the efficiency of this method in a wide range of cases: with different distributions laws, with systematical biases, and with different amount of measurements. The offered method allows obtaining positive results of the regulation for any earth-working process.

E. Podchasov, A. Terenteva
Three-Position Solenoid Valve for Pneumatic Systems of Trucks

The three-position solenoid valve is intended for use in the pneumatic system of the vehicles for drive and controls the gearbox by a microprocessor-based car engine control system. Supply voltage of three-position solenoid valve is 24 V, and its power is 14 W. The main design feature of the three-position solenoid valve is the absence of the synthetic sealing materials. The sealing surfaces of the solenoid valve are a metal surface with the microrelief in the form of successively alternating annular projections and depressions which increases the actual contact area of these surfaces. Any rubber and plastic sealing elements are completely absent in the designed solenoid valve. This technical solution allows one to significantly improve key indicators of valve quality, such as integrity, reliability, and durability of the valve up to 107 or more cycles of operation. An additional advantage of this construction of the solenoid valve is low cost of its production.

A. I. Nefed’ev, G. I. Sharonov, I. E. Ilyina
Investigation of Soil Destruction by Trench Chain Excavator Cutting Element Process

The article is devoted to the interaction of the cutting face of a scraper with a destructible medium during the development of a trench. Reducing the arising forces in the process of soil destruction can be achieved by various technical solutions. The simplest and least costly method is the method of the cutting elements design improving. The forces arising during the contact of the cutting element with the ground are considered. The interaction of the cutting element and the ground process is considered taking into account the stressed soil state before the cutting edge and the cutting angle digging and the cutting edge shape resistance effect. The calculated dependencies determining the scraper middle part width rational values and the scraper middle part boom rational parameters are obtained.

I. A. Teterina, P. A. Korchagin, A. B. Letopolsky
Improvement of the Extruder Construction

The paper describes the theoretical calculation of the process of processing the feed by creating a hydraulic shutter using the physical and mechanical properties of the material (the angle of pinching the material). Theoretical problems of the fundamentals of material deformation are considered, a scheme for calculating the effective forces for the creation of a hydraulic shutter is developed. In this case, the structural changes of the extruder screw are achieved by making the bevel angle of the screw extruder surface (View A). There are the theoretical analysis of the dependence of the torque on the viscosity of the feed, on the angle of the slope of the surface of the screw, analysis of the dependence of the power and capacity of the extruder on the speed of the screw and on the angle of the slope of the screw surface, on the viscosity of the feed. Analytical dependencies for the extruder output on its constructive-regime parameters during processing of feed are substantiated. The basic disadvantages are high power consumption of the process, insufficient performance, wear of the tool, and the others.

V. Kushnir, N. Gavrilov, T. Shkotova
New Roller Testing Unit for Vehicles

The paper is devoted to investigating a roller testing unit with a closed circuit for testing wheeled vehicles. A distinctive feature of the unit is its rigid connection between cylindrical surfaces which causes a kinematic mismatch between their angular velocities of rotation. The authors consider the power and kinematic interaction of a vehicle wheel with cylindrical surfaces in a new type of testing units, and find experimentally an interaction between the power and kinematic parameters of the contact between a tire and a cylindrical surface in the driving mode. A mathematical model of the testing unit with a closed circuit is developed to analyze the behavior of power flows at various mismatching transmission ratios. Therefore, some recommendations for choosing reasonable values of transmission ratios for various types of testing for wheeled vehicles are given. The proposed testing unit provides a constant value of skidding, which expands the diagnostic capabilities of testers of this type. It makes possible to determine the elastic and traction qualities of tires in all running modes (driven, driving, or braking), to carry out running, short time and braking testing for vehicles, to test tires for wear, heat resistance and strength, to carry out shafting tests of engines with and without loading, to test the turning mode with accelerated testing of differentials, and to simulate different ground conditions under wheels by providing different kinds of skidding.

I. P. Troyanovskaya, I. Yu. Novikova, I. S. Zhitenko
Modern State and Development of Grader Blades for Earth Moving and Snow Removal

The article discusses the modern state and development of grader blades for earth moving and snow removal. The grader blades of road machinery are made of different materials depending on the conditions in which they will be used. Modern polyurethane designs are not inferior to their performance characteristics of metal. New designs are being actively developed, and the existing designs of grader blades for snow plough are being improved to improve energy saving and cleaning efficiency of road surfaces from loose snow, packed snow and ice formations, as well as to ensure the safety of pavement and structures and to prevent damage to the blade and equipment of the base machine. The trends of a new principle of influence on the developed environment with the help of high-impulse vibrations are traced with the purpose of increasing the efficiency of snow-removal equipment. In the structures of the work tool of road construction machinery, disc cutters are used to improve the efficiency of soil destruction and snow–ice formations. The developed design of grader blades of a snow-removing machinery with installed disc cutters is presented. The proposed technical solution allows one to significantly increase the energy efficiency of the snow-removal process without increasing the power of the base machine.

A. V. Lysyannikov, V. G. Shram, Y. F. Kaiser
Optimizing Consumption of Gas Fuel Using Static Method of Tuning Automobile Gas-Cylinder Equipment

One of the promising areas in the field of vehicle operation is its conversion to gas fuel (natural gas and methane). Shuttle and taxi cars up to 80% are equipped with gas equipment. A number of automobile plants, both passenger and freight, are concentrated on the production of gas vehicles from the conveyor belt. The main advantages of using gas are significant economy, as well as reduced fuel consumption and toxicity. But with all the advantages of statistics, every second car, running on gas, works with fuel overruns. The analysis of observations from the practice of installing gas equipment indicates some averaging of environmental and economic norms. The adjustment and self-learning by the standard methods are carried out only with the movement of the car. At the same time, it is possible to fine-tune the gas-cylinder equipment on a static (stationary) car. The novelty of the proposed tuning technique is to create a wide range of load ranges for a working internal combustion engine. The loading is performed by the method of full and partial shutdown of the working cylinders. The necessary order of disconnection is provided by the diagnostic device—DBD-3. It is established that this method achieves a reduction in 1.1–2 times of fuel consumption and emission of toxic components.

A. V. Gritsenko, V. D. Shepelev, E. V. Shepeleva
Method and Means for Shutting Off Individual Cyclic Feeds of ICE and Their Use for Measuring ICE Speed and Load Characteristics

In large metropolises, the dominant share of environmental pollution is caused by automobile transport. In this connection, Euro-5 and Euro-6 environmental standards were affected in many countries. These standards require the use of technological innovations leading to significant reductions in harmful emissions and fuel consumption. At the same time, internal combustion engines using gasoline and gas fuel are actively used. Significant reduction in toxicity can be achieved by switching off fuel supply and the valve mechanism, as well as additional loading of the remaining cylinders with the power of mechanical losses of the cylinders, which are cut out. To achieve the research objective, which is to develop a method for measuring the engine speed and load characteristics, we designed a device—a gasoline engine loader (DBD-3) also being a full-time electronic ICE control unit. DBD-3 implements the technique of a full and partial cylinder cutout impacting the impulses of electromagnetic injectors and high-voltage circuits of the ignition system. In addition, several algorithms for performing tests and adjusting modes for the purpose of the ICE system adaptability are incorporated in the DBD-3 functions. These developments can be used to measure the ICE speed and load characteristics, as they allow achieving a high accuracy in setting the load effects, their smoothness, technological sophistication of all the methods and modes. In the future, the developed diagnostic means can be used as a built-in diagnostic tool and recommended for a wide use in the automotive industry.

A. M. Plaksin, Z. V. Almetova, A. E. Popov
Repair Kit Application with Spring Insert in Silentblock of Amortizor

The increase in the requirements for the sliding bearings quality which belong to one of the most widely used types of supports in many mechanisms, machines, devices, in various transport equipments, etc., and in demand in the domestic and international markets, is not only caused by high requirements of international standards, competition between enterprises that produce bearings, but also is associated primarily with the reliability and safety of machinery, especially vehicles—land, air, and water where failure of the bearing can lead to accidents, catastrophes accompanied by the great economic damage. The design of the sliding bearing for the reciprocating rotary motion is presented, which can be used in various units of transport engineering and technological equipment.

D. Kushaliyev, L. T. Shulanbayeva, B. A. Ermanova
Methodological Aspects of Diagnostics of Electric Gasoline Pumps in Operation of Automobiles

Statistical analysis shows that the fuel supply system of gasoline internal combustion engines takes the leading place in the number of failures. In particular, the failure of electric gasoline pumps is the first in line. The reliability of modern diagnostic methods in detecting EGP failures is at an unacceptably low level. At the same time, the existing standard self-diagnosis system also does not give the opportunity to recognize the malfunctions of the electric gasoline pump. Theoretical analysis shows that the detection of uncertainty makes it possible to use test diagnostic regimes consisting in changing the parameters of electric power, as well as in the operating modes of the engine. The regularities of the change in the EGP pressure by current values and voltage, as well as their interrelations with the technical state of the elements, are established in the article, the modes for determining the technical state of the EGP are theoretically substantiated, the method and technology of the process of diagnosing electric fuel pumps in terms of current parameters of current strength and EGP voltage in testing modes is developed. It is recommended for motor vehicles and auto-repair enterprises to use these methods to reliably determine the technical condition of an electric gasoline pump and other elements of the fuel supply system.

D. B. Vlasov, A. G. Ignatiev, Z. V. Almetova
Optimal Design of Steel Structure of Conveyor with Suspended Belt

The construction of a conveyor with suspended belt is represented. It consists of three basic design nodes—drive station, linear section, and tensioning station. The mathematical model of optimizing steel structures of the main design nodes is developed. They include the target functions of the drive station, linear section, tensioning station and improve mass and dimension parameters. The system design, strength and stiffness constraints are compiled. They are imposed on each target function. The universal structural diagrams are designed for steel structures of the drive station, linear section and tensioning station. They are subject to optimization and allow taking into account the presence of excess rods and a diagonal rod of a steel structure. The calculation of steel structures of the conveyor with a suspended belt was executed by LLC “Conveyor”. This conveyor is in maintenance. The comparative analysis of the steel structure of this conveyor with the steel structure of the similar conveyor with the suspended belt obtained in the process of optimal design is made. As a result, it is established that the mass of a steel structure has an excess margin of strength and stiffness. It is found viable to implement the optimal designing of a steel structure at the initial stage of its development. This will significantly reduce the weight of the suspended belt conveyor belt at the current operating condition.

P. V. Boslovyak, M. M. Jileykin
Determination of Scope of Two-Arm Concrete Placing Booms

The boom, with which the distribution and placing of concrete mix are carried out at the most crucial—the final stage, is an important element of the technology of concrete works. The use of equipment such as a concrete placing boom in contemporary monolithic technologies is steadily expanding. The concrete placing boom allows one to remove from the staff involved in the acceptance and pouring of the concrete part of the load associated with monitoring the correct operation of the concrete feeding equipment, and to focus fully on compliance with the technology of placing concrete. As a matter of fact, the boom is the final element of the pipeline transport of the concrete mixture, guiding it to the right place and at the right time for unloading, therefore, like cranes, it must have at least two mechanisms: one varying the reach and the other varying rotation. In this case, the mechanisms can have either a manual or hydraulic drive, respectively, they distinguish the mechanical booms (with manual control) and the ones with hydraulic control.

Ye. Koshkarev, M. Stepanov
Hardware Implementation of Automatic Control System for New Generation Magnetorheological Supports

Damping and vibration protection systems of equipment are necessary for industrial applications. In many respects, the existing fluid supports’ constructions for damping and vibration damping meets the requirements of industrial standards; they have some limitations and constructive disadvantages. The use of magnetorheological damping systems eliminates many disadvantages which are inherent to hydraulic dampers, but this leads to new operational problems, and they are inherent only to magnetorheological systems. The solution of these problems will improve efficiency and universalize magnetorheological dampers. Main disadvantages of magnetorheological systems are dependence on temperature stability of performances and significant heating of magnetorheological fluid in electromagnetic fields. The research paper presents methodological approaches to constructive solutions to these problems. It is considered as the original design of an adaptive combined rheological damper with magnetorheological chamber, which is control element of construction. Damping and vibration damping processes of a combined rheological damper includes magnetorheological, rheological and mechanical effects. It reduces the dependence on working environment temperature of performances. The effective method of combating environment heating is thermostating. The structure of a damping system has original rheological throttle-thermostat construction. The combination of new design solutions needs to create control algorithms, improve layout of devices and develop hardware implementation of control system and feedback. For ease of control and feedback implementation, there are selected devices which permist electrical measurements for non-electrical parameters. The text describes sensor arrangement in system and control algorithms for original devices. Component definition basics of multiparametric control and correction signals are considered. These relevant proposals allow simplifying and speeding up of sensor interrogation processes and correction of signals.

K. V. Naigert, V. A. Tselischev
Microturbine with Heat Exchanger with Regeneration Ratio Equal 95%

Using microturbines, which have very small emissions, seems to be very promising for Russia where using “green” energy is ineffective in most parts of its vast territory. There are significant opportunities for using microturbines in vehicles. Ordinary microturbines have smaller efficiency and therefore bigger fuel consumption than piston internal combustion engines. The increase in the efficiency of microturbines to the level of piston engines and higher can be obtained by using a heat exchanger with the high regeneration ratio (95–97%) and acceptable sizes. In this paper, the construction of such heat exchanger is presented. In addition, the results of the simulations are provided that show that using ceramics for making the heat exchanger’s disc makes it possible to significantly reduce deformation of the disc and therefore reduce air leakage. Other results of microturbine design are presented (the results of the thermodynamic calculations of the engine’s working cycle, the results of flow simulation in the compressor and turbine stages, and the results of flow and combustion simulation in combustion chamber). It is shown that a microturbine’s efficiency can reach 38% and there are possibilities to increase it further.

A. V. Kostukov, L. A. Kosach, A. S. Gornovskii
Study on Structure and Kinematics of Quick-Return Mechanism with Four-Bar Assur Group

The presented study shows results of structural and kinematic analysis of a planar six-bar quick-return mechanism that is used in shaping and planing machines for transformation of rotational motion of a driving link into prismatic motion of an end-effector. Assur groups of the III and II classes have been separated out from a quick-return mechanism when different driving links have been chosen during a structural analysis. Kinematic analysis has been carried out by grapho-analytical method for the case when a four-bar Assur group is included. Finally, 3D model has been simulated and coordinates of distinguished points of movable links have been found in six positions of the mechanism depending on the rotation of a driving link. The obtained results can be used in kinetostatic and dynamic analysis of the quick-return mechanism. The findings of the study can also be used in a design of planning and shaping machines, in synthesis and analysis of novel planar mechanisms.

A. Fomin, A. Olexenko
Optimization of Maintenance Service Parameters on the Example of Motor Transport Company Located in the North-West Region of the Russian Federation

In the paper, based on the analysis of the consumption of spare parts for internal combustion engines made by the Cummins Company and used by the LLC PITERAVTO motor transport company, the necessity of quite a substantial reorganization of maintenance and logistics services is justified. Such reorganization would certainly improve the economical performance of the service. It is noted that a poorly developed system of technical service and rolling stock utilization, such as logistic service, leads to higher costs of component materials, spare modules and units, and also increases the downtime of equipment due to unproductive reasons. As a method of optimizing the maintenance service parameters for the area covered by transport services, the center-of-mass method is used. The paper formulates the goal function and considers the constraints set to ensure the practical application of this method. Using the method would allow to optimize such parameters of managing technical service and rolling stock utilization in a motor transport company as the optimal number of service centers, their locations, staff and equipment, as well as to define requirements for the organization of warehouse services in terms of the spare parts nomenclature, periodicity of supplies, etc., which, in turn, could reduce the expenditures on spare parts and components and improve technical-and-economical performance of the whole company.

O. Ognev, A. Yanikov, Y. Stroganov
System Approach Realization Under Compressed Air Quality Increase Strategy Choice Based on Resource Saving

At present, the problem of the compressed preparation (drying and purifying) at the railway rolling stock and enterprises has no single unique solution. The authors try to analyze and systemize the mechanical method for compressed air preparation at the mains of charging and testing breaks device at car depots. It is suggested to use SWOT analysis as the key to analyze strong and weak sides of the method and consider the possible opportunities and threats of its implementation. As an example, the pneumatic system of the “Bataysk-Sever” car exploitation depot is considered for the implementation of energy-saving-compressed air purification systems. The jalousie separator placed in tanks is suggested as an energy-saving technology to be applied for the compressed air purification at pneumatic systems.

T. Ripol-Saragosi, L. Ripol-Saragosi
Operation Parameters Matching for Main Mechanisms of Open-Pit Excavators Employed in Rock Excavation

It is shown that operation parameters of the main mechanisms of an open-pit excavator (hoisting and thrusting velocities) vary within a wide range during the process of rock excavation. Based on the computing experiment aimed to calculate EKG-20A excavator parameters, hoisting and thrusting velocities were determined for a specified law of bucket motion (top of the cutting edge) within the work area of an excavator. Analytical dependencies were derived, which could be used to obtain required correlations between hoisting and thrusting velocities to move the bucket along equidistant paths at various inclination angles. Assuring agreement of operation parameters for the main mechanisms of open-pit excavators employed in rock excavation would allow one to increase the efficiency of their functioning. The results of the research could also serve as a basis for developing an adaptive system which would control the working process and enhance the performance of the excavator as a whole.

O. Lukashuk, A. Komissarov, K. Letnev
Distribution of Consumed Power Between Drives of Main Mechanisms in Open-Pit Excavators During the Process of Rock Excavation

It was established that during the process of excavation realized by an open-pit excavator, the joint action of drives powering its main (hoisting and thrusting) mechanisms changes the levels of power consumed both by those drives individually and by the power unit as a whole. A computing experiment was used as the research method. It was run for the EKG-20A excavator made by JSC “Uralmashplant” and on the basis of a simulation model for the process of excavation realized by the front-shovel operational equipment. Main factors were determined which could define how the power consumed is distributed between the drives of the main mechanisms. A method was proposed to calculate the power characteristics of an open-pit excavator working up the excavation face in specified mining and operating conditions on the basis of the simulation model. Estimating the power characteristic would allow one to determine a rational scheme of excavation works.

O. Lukashuk, A. Komissarov, K. Letnev
Research of Dynamics of Hydraulic Loader Crane in Case of Conjoint Movement of Sections

Maintenance documentation to regulate the work of hydraulic loader cranes allows one to combine the implementation of the movement of several boom sections over time. For that purpose, the operator of the loader crane activates several hydraulic control valves simultaneously. In comparison with the case of separate movement of sections, conjoint movement of sections leads to the changes in the mechanical tension level of supporting iron of a loader crane. Conjoint movement makes it possible to reduce overcoming efforts of the hydraulic cylinders, with positive effects on capacity and power efficiency of a loader crane. To access the impact of these phenomena on dynamics and loading of loader cranes using the developed mathematical model, there was conducted a computer simulation of dynamics when sections move conjointly. The results of this simulation were confirmed by the experimental research. The method of the experimental research involves video recording of loader crane movements with further processing obtained recordings using the Kinovea software. The experimental research made it possible to reveal a random scatter of a loader crane speed and acceleration values because of the manual control. It was found that the combination of movements of loader crane sections, which are connected only by hydraulic hinges, allows one to reduce the cycle time of 10–40%. In turn, a combination of pivot and telescoping section movements over time leads to changing efforts overcome by hydraulic drive of 30–40%. At the same time, efforts in hydraulic drive can both increase and decrease.

I. A. Lagerev, A. V. Lagerev
Selection of Mixers for Preparation of Quality Building Mixtures

The preparation of building mixtures is a large segment of the construction industry and the testing base of the mixing equipment. The proposed mixing equipment does not always ensure the preparation of quality building mixtures. Therefore, the issue of choosing a reliable mixing equipment is relevant. The problem of a rational choice of mixing equipment for the qualitative preparation of various mixtures is disclosed. An important condition when choosing equipment is to improve the quality of mixing and mechanization of work. To solve the problem, the analysis of design and technical and economic indicators of mixing equipment was carried out. Dependencies are established, binding internals of mixtures with its composition and technical characteristics of the proposed mixers are obtained. The ways of mixer rational selection providing for a high degree of uniformity of mixtures are recommended. The rational speeds of the working bodies of the mixers are proposed. The dependences of the Reynolds number on the rotational speed of the mixing drum and the diameter, between the power and the diameter of the drum, are established. The proposed method of choosing a rational nomenclature of technological equipment for mixing will significantly reduce the cost of operating mixed machines and improve the quality of mixtures.

B. A. Kaitukov, M. A. Stepanov
Hydraulic-Drive-Relieving Device for Road Construction Machines

Modern specialized and general-use machines intended to work on the ground surface are equipped with a hydraulic drive of working attachments. Hydraulic-driven machinery and packaged tools are better in terms of speed and the evenness of the reverse or differential control of working attachments, changing the working machine position, the accuracy of positioning, dosing the force’s action on the working attachments, etc. The working pressure in hydraulic drives has been optimized. However, there is a possibility of unauthorized discharge of hydraulic fluid. Therefore, an innovative engineering solution is suggested for the protection of hydraulic drives. The analysis of the operation modes of road construction machines and other traction transport vehicles shows that high-pressure hoses of the hydraulic system are destructed and the hydraulic fluid is discharged into the atmosphere even under nominal operation conditions, which affects the ecological safety of the environment including the fauna and flora.

N. A. Fomenko, S. V. Aleksikov, S. G. Artemova
Improvement of Acoustic Characteristics of Motor Vehicle Intake System Based on Calculation and Experimental Research

The article considers the technique and results of computational studies of the acoustic characteristics of the elements and the motor vehicle intake system. It describes the purpose and operation characteristics of the intake system. It is noted that the waves occurring in the intake tract, the nature of which depends on the geometry of the intake tract and the operating mode of the engine, determine the acoustic characteristics of the intake system and can improve or worsen the filling of the cylinders. Adding Helmholtz resonators to the manifolds improves the acoustic characteristics of the intake system depending on the engine speed and maximizes filling of cylinders for different speed modes. This allows to increase the power, economic, environmental performance of the engine and reduce the gas-dynamic noise emitted by the cutoff of the intake tract. A resonator was developed on the basis of finite element modeling to replace the connecting pipe of the air supply hose of hot air for improving the acoustic characteristics of motor vehicle intake system. The range of transmission loss (TL) of intake system has been calculated to evaluate the performance of the elements and the intake system in acoustical performance. The overall level of sound pressure at idling speed is determined by radiation in the frequency range 100–5000 Hz. In this range, in most one-third octave, the resonator lowers the sound pressure up to 5 dBA.

G. G. Nadareishvili, V. V. Galevko, R. I. Rakhmatov
Evaluating the Effectiveness of the Cable Excavator Bucket Swing Mechanism

The paper presents the results of experimental and analytical study of the innovative, non-driven mechanism of the cable excavator bucket swing. This required a mathematical model of the digging workflow to be complemented with the necessary technical characteristics of the working body elements, including hydraulic cylinders, performing the role of kinematic links of variable length and their connecting pipelines in the adopted mechanism scheme. The results obtained on the basis of the mathematical model were verified by the experiment and proved to be quite a reliable tool that can simulate the bucket swing mechanism operation in a variety of production conditions on different types of cable excavators.

V. S. Isakov, V. P. Maksimov, Y. V. Maksimov
Improving the Construction of Magnetic Clutch Amplifiers of Locomotive Wheels with Rails

The ways of improving the design of the magnetic coupling amplifiers of locomotive wheels with rails are considered. A description of the clutch strengthening devices and the principle of their operation with the magnetic core and the coil between the wheelsets parallel to the sleepers, above the rails, allows to increase the magnetic flux passing through the contact of the wheels with the rails, to increase the coefficient of adhesion between the wheels and rails, thereby increasing the locomotive productivity, is given. The parameters of the magnetic field are determined, the graphs of the change in the field induction in the zone of contact of the wheel with the rail on the inductor magnetizing force are plotted.

D. Ya. Antipin, V. I. Vorobiev, M. A. Maslov
Technique of Increasing Passenger Comfort by Ensuring Rational Parameters of Flexural Stiffness of Bodies of Passenger Cars

Based on the analysis of simulation results and full-scale running tests conducted by domestic and foreign specialists, the natural frequencies and vibration modes of the body bearing structure, which have the greatest impact on the passenger comfort level and safety, are determined. Design measures are proposed to ensure an increase in safety and comfort of transportation in domestic passenger cars through the installation of an additional load-bearing partition in the middle section of the body, which also ensures the requirements for the passive safety of a car as well as the introduction of additional longitudinal elements in the frame supporting structure.

D. Ya. Antipin, E. V. Lukashova
Features of Decision-Making Simulation When Designing Locomotive Underframe Part

The analysis of the logic of choice of design options for the locomotive underframe part is carried out. It is established that the solution of the problem situation in the choice of the design of the units of the outfit part is the development of a multivariate strategy for creating and mastering the production of various design variants. A new design of the traction drive is proposed and patented, instead of a technologically complex integrated axial thrust drive, it is offered to use a support frame drive with an axial reduction gear at the early stages of implementation, with a subsequent transition to an axle-type traction drive of the aggregate type, combining high processability and the possibility of reducing the TM weight.

V. I. Vorobiev, O. V. Izmerov, S. O. Kopyilov
Modernization of Gas Purifying System in Bus Methane Feed System

The present paper considers a topical problem of a fuel feed system installed on a bus powered by methane gas, the problem c the consisting in a condensed substance in the cylinders. The main difficulty in solving this problem is that the condensed substance accumulated in the cylinders cannot be removed since the cylinders are mainly horizontally installed. Hence, the accumulated condensed substance cannot outflow from the cylinder. To remove the condensed substance from the cylinders one should release the compressed natural gas from the feed system, disconnect the cylinders, to clean them and then to connect and to fill them with gas. This is not a very efficient and cost-effective method to solve this problem. The comparison of the cylinder structure for the compressed natural gas with cylinders with a liquefied gas helps to find the way to eliminate the problem. It should be noted that the tube should fit a particular type of cylinder, located in parallel with the wall at the bottom to fully take the condensed substance from the cylinder. Along with that, after an already used cylinder or a new cylinder is upgraded, the marks should be made at the valve of the upper part and lower part of the cylinder. In case the cylinder has a wrong position, no condensed substance will be removed from it. The upgraded feed system allows one to prolong the period of regular technical maintenance of the cylinders, as well as to reduce the labor contribution in repair works and maintenance of the feed system.

Yu. I. Moiseev, A. V. Popov, K. A. Badikov
Hyperbolic Steering for Tracked Vehicles

Turning mechanisms provide for a curvilinear motion of the tracked vehicles through variations of tractive force and track rotation speed along the sides. The article defines basic parameters and provides the drawings of kinematic diagrams for hyperbolic steering of tracked vehicles delivering nonlinear relation between the values of fixed steering radius and travel speed. These mechanisms improve vehicle control and time of corner and reduce the likelihood of skidding of a tracked vehicle. This type of mechanisms is characterized by nonlinear (in the examined case—hyperbolic) dependency between values of specified (fixed) steering radius and vehicle travel speed. As a result, the authors develop a methodological framework for drawing kinematic diagrams for hyperbolic turning mechanisms and attain diagrams, which are practicable for the transmission of drives of modern fast (transporting) tracked vehicles.

R. Yu. Dobretsov, A. V. Lozin, M. S. Medvedev
Theoretical Study of the Vibrations Transmitted to Frame from Internal Combustion Engine of Locomotives and Diesel Locomotives and Their Influence on Labor Conditions of Locomotive Crews

The paper is devoted to the creation of the track machines with high power and productivity. In the constructions of them, the vibroactive working bodies are widely used, and it is inevitably accompanied by an increase in vibro-acoustic characteristics. The consequence of this is not only the deterioration of the labour conditions for motorists and locomotive crews, but also for acoustic and vibration effects on the residential area when it is operating in the residential development. One of the main sources of the vibration effects of locomotives and diesel locomotives is an internal combustion engine mounted on a load-bearing frame where the driver’s cabs are set. To develop practical recommendations for reducing vibration levels at workplaces of locomotive crews and machinists to sanitary standards, it is necessary to study the regularities in the formation of the vibration spectra in the corresponding frequency ranges. Therefore, in this article, we present the results of the theoretical studies of natural vibration frequencies of the main vibration source of the internal combustion engine and the vibration levels created at the attachment points to the base frame and the attachment points of the driver cabs which determine factually the choice of the engineering solutions for vibration protection systems.

I. A. Yaitskov
Choice of Destruction Criteria of Cylinder Heads of Piston Engines

During the creation and debugging of newly designed prototype of a piston engine, the main attention should be focused on the achievement of the technical requirements of durability of heat-stressed parts of piston engines surrounding the combustion chamber. These details are in thermal, power, kinematic interaction during operation of the internal combustion engine. When the engine is operating in transient modes, stresses occur in the cross sections of the cylinder head of piston engine not only from the action of gas forces, but also large stresses arise from temperature changes, since temperature over the period of the cycle changes. The temperature in the combustion chamber varies cyclically. Similarly, the thermal stresses vary cyclically. Variable stresses during a many loading cycles will lead to the crack in a cylinder head. It is necessary to choose those models for the calculation of a heat-stressed condition which would allow to find the durability of the cylinder head with high efficiency. The failure criterion of the heat-stressed parts of internal combustion engines is considered. The maximum strain criterion is used at viscous destruction. This criterion represents the sum of the ratio of the increment of the degree of damage to the magnitude of the plastic strain approaches unity. We examine the hypothesis of a linear summation of damages for the calculation method of the durability of the cylinder heads.

A. N. Gots, V. S. Klevtsov
Design of the Inductor as Knot of the Electromechanical Converter with a Secondary Discrete Part

The new approach to design and research of the electromechanical converter with a secondary discrete part based on the analysis of the movement of a secondary discrete part is offered. The configuration is defined and optimizing calculation of the inductor of the electromechanical converter with a secondary discrete part is executed. As a method of optimization, the stochastic method of random variables of Monte Carlo has been used. Optimization is executed in two stages with the application of a software package of FEMM 4.2. As a result of optimization, the geometrical sizes of a tooth zone of the inductor of the device are received. The research of change of the electromagnetic effort operating on a single ferromagnetic element in the working camera at the change of geometry of a tooth zone is conducted. The geometrical sizes of elements of a tooth zone of the inductor providing the best conditions of movement of a secondary discrete part on the volume of the working camera are determined.

D. N. Kuimov, A. V. Pavlenko

Equipment and Technology of Welding Production

Frontmatter
Welding and Build-Up Technologies at Dredge Scooping Pin Manufacture and Renovation

The purpose of the development is to determine the possibility to manufacture welded dredge scooping pins providing for the structure operational capacity as well as to find out how to repair and reinforce such pins to extend their service life. The pins are used to connect dredge scoops into a scoop chain at gold and diamond dredges. The quality of pins significantly influences the stable operation of a dredge scoop mechanism, its early wear-out or destruction can lead to the increase of the load imposed on the mechanism drive and even to a self-induced scoop chain descending which is a crucial breakdown and can cause significant damages. At the moment, the key method to manufacture the pin dies is hot stamping which is very expensive and requires cooperation with the companies possessing high-power stamping facilities. Methods: The authors propose using a welded pin design instead of the one-piece forged one as well as the technology to renovate the worn-out pins. The authors conducted the research on the connection and build-up metal structure and their mechanical properties. Materials: The authors managed to choose a doping pattern and determine the welding and build-up metal chemical content. The research results ascertained the possibility to use the welded pin design and the development of the welding and build-up technology at prefabrication as well as the technology for remanufacturing of worn-out pins at gold-mining companies. Conclusion: The production of the developed materials and the welded pin manufacturing technology were adopted and implemented by the Irkutsk Heavy Machinery Plant (IZTM), while a number of gold-mining companies adopted the technology allowing for the worn-out pin renovation.

V. L. Broido, S. S. Chernyak
Investigation of Wire Feed Control Channel in Additive Manufacturing Unit

The structure, composition, and characteristics of a device for feeding a filler wire to an electron beam additive manufacturing unit are described. The analysis of the results of experimental technological processes is carried out and the relevance of considering the wire feed channel as one of the main control channels is proved, for the effective use of which feedback speeding is required. The analysis of existing methods of measuring feed speed is carried out and a noncontact measurement method based on the use of a multi-element matrix sensor and infrared illumination is proposed. A measurement scheme is described, which includes a computer, as well as a module for data collection and control. The experimentally obtained dynamic characteristics of the control channel of wire feed speed are presented. The analysis of the obtained oscillograms of the armature winding voltage and the signal of the wire feed speed is carried out, and the possibility of using the proposed sensor for constructing feed speed stabilization system is justified.

D. A. Gaponova, A. V. Shcherbakov, R. V. Rodyakina
Measurement of Residual Stresses in Thin-Sheet Welded Constructions of Low-Alloyed Steel

The concentrated heat source causes strong local heating of the metal during arc welding. The molten metal is cooled comparatively quickly. Its volume is reduced during solidification, shrinkage occurs and the density of the weld seam metal increases. During welding, the molten and solid metals are inseparable. During solidification in the weld seam metal and the heat-affected zone, changes of the microstructure take place that influence the nature of the distribution, the sign and value of residual stresses. Longitudinal and transverse internal stresses occur. When the stress value reaches the yield limit, plastic deformation occurs in the metal, and the shape and dimensions of the workpiece changes. Adverse tensile residual stresses reduce the vibration strength of welded constructions. The weld seam stresses differ in the gradient and complex nature of the distribution in different directions. The influence of residual stresses on the fatigue resistance will be different for various areas of a welded joint. Simulation and calculation methods do not accurately determine the value of residual stresses. The article presents the technique of residual stress measurement by an X-ray diffraction method. Residual stresses were directly determined on the surface of the weld seams. Single butt welds and single bevel butt welds of low-alloyed sheet steel with 0.9% C-2% Mn-0.8% Si have been investigated. The stress tensor at different sites of welded joints was calculated. The results demonstrate the influence of nonequilibrium crystallization on the nature of residual stresses formation. The interrelation between residual stresses and structural transformations occurring in the weld metal was shown.

E. P. Nikolaeva, A. Yu. Nikolaev
Filler Wire-Feeding Device

The device for feeding the surfacing electrode or filler wire to the combustion zone of the electric arc is intended for restoring the parts of the machines by surfacing, for example, by high-speed argon-arc surfacing, and for conferring special physical and mechanical properties to the surface of the part during its manufacturing. There are aligning bushings in the body of the wire feeder. The thickness of the bushings is from two to three diameters of the surfacing wire. The device, on the one hand, increases the productivity of the process up to 10 times according to the surface area deposited per unit of time with minimal allowances for subsequent machining, and on the other hand, increases other parameters of high-speed argon-arc surfacing. At the same time, the service life of the surfacing unit is becoming longer due to rectilinear rotation of the filler wire around its axis at the output of the wire feeder mechanism. It is the usage of this device that makes the process of high-speed argon-arc surfacing possible. The device provides six–tenfold increase in productivity on the surface area deposited per the unit of time, reducing energy costs per unit of the weld area by 2 or 3 times and reducing the thermal input to the workpiece by 2 or 3 times in comparison to the conventional argon-arc surfacing.

L. I. Korolkova, A. V. Herreinstein, N. Mashrabov
Kinetics of Contact Interaction Between Dissimilar Solid Materials by Pressure Welding with Heating

The purpose of the work is to select materials and develop a technology for welding them with single-crystal sapphire disks at a temperature not exceeding 1200 °C and a compression pressure of not more than 14.7 MPa. The kinetics of dissimilar materials bond strengthening has been analyzed based on the data on the kinetics of micro-asperity plastic deformation forming of physical contact and fractography of welded surfaces of titanium, iron–nickel 50N alloy and synthetic single-crystal sapphire. The specificity of producing a vacuum-tight permanent connection of single-crystal sapphire with titanium and 50N alloy (for devices of electronic equipment) at temperatures not more than 1200 °C and compression pressure up to 14.7 MPa was considered.

V. V. Abramov, Yu. P. Rakunov
Determination of Functional Relation Between Parameters of Weld Penetration Shape and Measurable Output Variables in Electron-Beam Welding Process

Parameters of weld penetration shape (depth and width) are subject to a nonstationary change during the process of electron-beam welding because of the effect of uncontrolled disturbances. This is unacceptable, especially for welding products of critical use. The lack of information about weld penetration shape during the process of welding dictates the need for periodic welding of reference specimens for its control, which reduces the efficiency of the EBW-technology. In this paper, an experimental approach is considered that makes it possible to determine a functional dependence between the parameters of a weld penetration shape and measurable output variables in the electron-beam welding process based on the energy balance of the beam in a vapor-gas crater. The presence of such an equation of connection makes it possible to carry out the current control over the formation of a weld penetration shape of the welded joint. The introduction of control or management of the current shape of weld penetration ensures the reliability of requirements’ realization of this technology.

V. N. Lastovirya, A. A. Cherepakhin, R. V. Rodyakina
Computer Modeling of Residual Stresses and Strains at Arc Welding by Modulated Current

The article reviews the investigations of forming residual stresses and strains at arc welding by the modulated current. The maintenance of a favorable thermal cycle in a zone (that is close to a joint) is very important at welding many metals and their fusions. By changing a thermal cycle it is possible to reduce a grain value, to achieve a minimal speed of increasing elastoplastic strains in a zone of high temperature, to control a cooling rate and thus to receive favorable structures in a zone near to a joint. The numerical modeling of thermo-deformation processes of thin plates at arc welding by the modulated current is suggested in the paper. The complex of investigations depends on various technological parameters. The comparison of the received calculation data with experimental data has shown the acceptability of the positions and suppositions accepted in the design model.

M. Nurguzhin, G. Danenova, T. Akhmetzhanov
Study on the Dispersion of Concentrator Geometric Parameters in Fillet-Welded Joints

The article shows the necessity to have information about the real relief formation in the coupling zone in various welding methods and regimes in order to estimate the local strength of fillet-welded joints. It is shown that the existing method of radii and coupling angles selection leads to significant errors, and in some cases is controversial. A technique for experimental investigation of the geometric parameters of the coupling zone is proposed. The regularity of dispersion of radii and transition angles for various technological methods and welding regimes is established on the basis of statistical processing of a large array of experimental data. The study of the established regularities for ergodicity and stationarity made it possible to assume that the geometrical parameters of the coupling zone of fillet-welded joints being made with similar welding regimes will be repeated.

L. Shron, V. Bogutsky, E. Yagyaev
Numerical Analysis of Surface Formation of Titanium Parts During Direct Laser Deposition

The calculation method for determining technological mode parameters of the direct laser deposition process has been developed taking into account the features of a bead surface formation for titanium alloys. A method for solving the equilibrium equations of the liquid phase in the gravity field was proposed. This solution allows determining the deposited bead shape with a high accuracy and a minimal cost of computing resources. A comparison of calculated and experimental data of deposited bead parameters was presented. The DLD tests were carried out using VT6 (Ti6Al4V) powder and substrate. The highest error value does not exceed 6%. Thus, the calculation method for the deposited bead shape satisfactorily describes the process of heat transfer during the DLD process and can be used for preliminary selection of the process parameters. It is also established that the process parameters have a significant influence on the surface roughness of the grown part.

S. Ivanov, E. Valdaytseva, S. Stankevich
Optimization of High-Speed Direct Laser Deposition Regime Parameters in Titanium Blades Production

The article is devoted to the technology of high-speed direct laser deposition of Ti-6Al − 4V titanium alloy samples. The paper aims at the development of the production technology of titanium blisc for machining. Natural experiments were conducted to select optimal process regimes ensuring the absence of defects in the form of pores, fusions, cracks; samples of various configurations for mechanical testing were also produced. As a result, the optimal parameters of high-speed direct laser deposition regime, ensuring the formation of a defect-free structure and optimal mechanical properties of the samples, were established. The oxygen level, at which it is possible to obtain products with mechanical properties matching those of Ti-6Al − 4V alloy, obtained with traditional methods, content in the chamber, is also established. A blisc model from a powder titanium alloy Ti-6Al − 4V was made using optimal regimes under the method of high-speed direct laser deposition.

P. A. Golovin, A. M. Vildanov, K. D. Babkin
Tungsten Electrode Fracture in Submerged Arc Welding Process

The article describes the results of studies on the fracture of tungsten electrodes with an increased arc discharge stabilization rate during the submerged arc welding of titanium structures. The complexity of welding is due to thick-walled parts and a current rate of more than 1600 A. Under this mode, the changes in the geometry of a penetrated electrode and destruction of its working zone occur. It results in major defects—formation of higher melting inclusions in welding joints. The X-ray analysis was used to study welding joints for Ti–Al–Zn. The influence of welding modes and chemical composition of electrodes with 1.1–1.4% LaO and Y2O3 added on the erosion wear and destruction of the working edge of electrodes as well as the presence of tungsten inclusions in welding joints were identified. The chemical composition of the electrode material was tested by means of spectral analysis. Using the research results, the stages of the process reflecting the mechanism of destruction of lanthanum/yttrium oxide tungsten electrodes in the submerged arc welding of thick-walled titanium structures were described.

N. Astafeva
Metadaten
Titel
Proceedings of the 4th International Conference on Industrial Engineering
herausgegeben von
Prof. Andrey A. Radionov
Prof. Oleg A. Kravchenko
Prof. Victor I. Guzeev
Prof. Yurij V. Rozhdestvenskiy
Copyright-Jahr
2019
Electronic ISBN
978-3-319-95630-5
Print ISBN
978-3-319-95629-9
DOI
https://doi.org/10.1007/978-3-319-95630-5

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