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1
Content available Control of the parameters of the surface layer of steel parts during their processing applying the material homogeneity criterion
Kusyi Yaroslav, Stupnytskyy Vadym, Kostiuk Olha, Onysko Oleh, Dragašius Egidijus, Baskutis Saulius, Chatys Rafał
Eksploatacja i Niezawodność
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2024
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Vol. 26, no. 3
art. no. 187794
EN
The main goal of the presented research is to assess the technological damageability of the material and use this as a criterion for analyzing the technological route of product machining in the "blank-workpiece-final part" technological chain. This technological chain is examined in detail in the most important stages of the life cycles of mechanical engineering products aiming to take into account the principles of technological inheritability of their characteristics and quality parameters. The technological inheritability of the properties of the surface layers of the made of steel parts of machines and mechanisms during their machining evaluates and predicts the transformation of the structurally heterogeneous material obtained after the production of blanks into the structurally homogeneous material of the final parts. The procedure for evaluating the homogeneity of the processed material for each technological step by the LM hardness method is presented according to the calculated values of the Weibull homogeneity coefficient, material constant, variation coefficient, technological damageability along with corresponding intensity of the expansion. The developed methodology was implemented and proven at the manufacturing process of the conveyor belt drive drum shaft.
2
Content available Hob wear prediction based on simulation of friction, heat fluxes, and cutting temperature
Hrytsay Ihor, Stupnytskyy Vadym
Archive of Mechanical Engineering
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2023
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LXX, nr 2
271--286
EN
Based on comprehensive interrelated mathematical and graphical-analytical models, including 3D cut layers and simulation of contact, strain, force, and thermal processes during gear hobbing friction forces, heat fluxes, and temperature on the teeth of the hob surface are investigated. Various physical phenomena are responsible for their wear: friction on contact surfaces and thermal flow. These factors act independently of each other; therefore, the worn areas are localized in different active parts of the hob. Friction causes abrasive wear and heat fluxes result in heat softening of the tool. Intense heat fluxes due to significant friction, acting on areas of limited area, lead to temperatures exceeding the critical temperature on certain edges of the high-speed cutter. Simulation results enable identification of high-temperature areas on the working surface of cutting edges, where wear is caused by various reasons, and make it possible to select different methods of hardening these surfaces. To create protective coatings with maximum heat resistance, it is advisable to use laser technologies, electro spark alloying, or plasma spraying, and for coatings that provide reduction of friction on the surfaces – formation of diamond-containing layers with minimum adhesion properties and low friction coefficient on the corresponding surfaces.
3
Content available Comprehensive system for simulation of vibration processes during the titanium alloys machining
Stupnytskyy Vadym, Xianning She, Novitskyi Yurii, Novitskyi Yaroslav
Archive of Mechanical Engineering
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2023
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LXX, nr 1
85--105
EN
Titanium alloys are difficult-to-machine materials due to their complex mechanical and thermophysical properties. An essential factor in ensuring the quality of the machined surface is the analysis and recommendation of vibration processes accompanying cutting. The analytical description of these processes for machining titanium alloys is very complicated due to the complex adiabatic shear phenomena and the specific thermodynamic state of the chip-forming zone. Simulation modeling chip formation rheology in Computer-Aided Forming systems is a practical method for studying these phenomena. However, dynamic research of the cutting process using such techniques is limited because the initial state of the workpiece and tool is a priori assumed to be "rigid", and the damping properties of the fixture and machine elements are not taken into account at all. Therefore, combining the results of analytical modeling of the cutting process dynamics with the results of simulation modeling was the basis for the proposed research methodology. Such symbiosis of different techniques will consider both mechanical and thermodynamic aspects of machining (specific dynamics of cutting forces) and actual conditions of stiffness and damping properties of the “Machine-Fixture-Tool-Workpiece” system.
4
Content available Optimization synthesis of technological parameters during manufacturing of the parts
Kusyi Yaroslav, Stupnytskyy Vadym, Onysko Oleh, Dragašius Egidijus, Baskutis Saulius, Chatys Rafal
Eksploatacja i Niezawodność
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2022
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Vol. 24, no. 4
655--667
EN
Technological ensuring the reliability of machine parts is realized by failing to reach the limited state of the elements of the technological system: machine – clamping device – metal-cutting tool-part. A method of optimization synthesis of parameters of technological processes of manufacturing machine parts has been developed. Testing the developed methodology, it was found that the metal cutting tool is Meanwhile, research has shown that metal cutting machine has the least influence on the formation of detailed quality-adjustable parameters from all the the weakest element of the technological system in terms of reliability and has the greatest impact on the quality of machined parts. elements of the process media "machine – clamping device – cutting tool". Finally, a concrete example is provided to demonstrate the effectiveness of the proposed method. The proposed technique has been successfully tested for the manufacturing process of the reduction-gear housing.
5
Content available Simulation of loading and wear rate distribution on cutting edges during gears hobbing
Hrytsay Ihor, Stupnytskyy Vadym, Topchii Vladyslav
Archive of Mechanical Engineering
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2021
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LXVIII, nr 1
51--76
EN
Results of complex mathematical and computer simulation of gear hobbing are given. A systematic approach to research allowed for the development of simulation models and sequencing of all aspects of this complex process. Based on the modeling of non-deformable chips, a new analytical method for analyzing hobbing has been proposed. The shear, friction and cutting forces at the level of certain teeth and edges in the active space of the cutter are analyzed depending on the cut thickness, cross-sectional area, intensity of plastic deformation and length of contact with the workpiece has been developed. The results of computer simulations made it possible to evaluate the load distribution along the cutting edge and to predict the wear resistance and durability of the hob cutter, as well as to develop measures and recommendations for both the tool design and the technology of hobbing in general. Changing the shape of cutting surface, or the design of the tooth, can facilitate separation of the cutting process between the head and leading and trailing edges. In this way, more efficient hobbing conditions can be achieved and the life of the hob can be extended.
6
Content available Comprehensive analysis of tribological factor influence on stress-strain and thermal state of workpiece during titanium alloys machining
Stupnytskyy Vadym, She Xianning
Archive of Mechanical Engineering
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2021
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LXVIII, nr 2
227--248
EN
The article describes how different friction coefficients under certain cutting conditions and parameters affect the formation of the stress-strain and thermal states of the product when titanium alloy machining. A new research methodology is used for the study. Firstly, in the initial data for simulation, each time a different declared coefficient of friction is proposed, and every such task of the cutting process modelling is solved for various cutting parameters. The second stage analyzes how these coefficients influence the stress-strain and thermodynamic state of the workpiece and tool during cutting, as well as the tool wear dynamics. In the third stage of the study, ways for ensuring these analytically-grounded tribological cutting conditions are proposed. The analysis of different wear criteria in the simulation models of titanium alloys cutting is carried out. Experimental studies confirm simulation results.
7
Content available Optimization model for planning set of measures to prevent occupational injuries in machine-building enterprises
Stupnytska Nataliya, Stupnytskyy Vadym
Journal of KONBiN
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2020
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Vol. 50, iss. 1
117--129
EN
Criteria of occupational injuries potential risk in the machine-building industry are described in the article. Systemic analysis of the structure of the measures to prevent occupational injuries is given. Main tasks to reduce the risk of industrial injury at the machinebuilding enterprise are analysed. The methodology for optimal planning of accident prevention measures at the machine-building enterprise is described. A mathematical interpretation of the problem is given. The objective function is an argument of the maximum integral effectiveness for the set of planned measures to prevent occupational injuries. Constraint set of the optimization model describes the impossibility to exceed the allowable limit of cost, the feasibility and the possibility of implementing the measure’s plan reasoning from the technological and construction requirements of existing production engineering.
PL
W artykule opisano kryteria potencjalnego ryzyka urazów w pracy w przemyśle maszynowym. Podano analizę systemową struktury środków służących zapobieganiu urazów w miejscu pracy. Dokonano analizy głównych zadań mających na celu zmniejszenie ryzyka urazów w przedsiębiorstwach budowy maszyn. Przedstawiono matematyczną interpretację wspomnianego problemu. Funkcja celu jest argumentem maksymalnej integralnej skuteczności w odniesieniu do pakietu środków służących zapobieganiu urazów w miejscu pracy. Ograniczony pakiet modelu optymalizacyjnego opisuje niemożność przekroczenia dozwolonego limitu kosztów, wykonalność oraz możliwość wdrożenia uzasadnionego planu działania na podstawie wymagań technologicznych i konstrukcyjnych istniejącej technologii produkcji.
8
Content available Comprehensive analysis of the product’s operational properties formation considering machining technology
Stupnytskyy Vadym, Hrytsay Ihor
Archive of Mechanical Engineering
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2020
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LXVII, nr 2
149--167
EN
Product Lifecycle Management (PLM) system requires consideration and ensuring efficient operating conditions for the most loaded parts in the product, not only at the product’s design stage, but also at the production stage. Operational properties of the product can be significantly improved if we take into consideration the formation of the functional surfaces wear resistance parameters already at the planning stage of the technological process structure and parameters of the product’s machining. The method of constructing predictive models of the influence of the technological process structure on the formation of a complex of product’s operational properties is described in the article. The relative index of operational wear resistance of the machined surface, which is characterized by the use of different variants of the structure and parameters of this surface treatment, depends on the microtopographic state of the surface layer and the presence of cutting-induced residual stress. On the example of the eject pin machining it has been shown how the change in the structure of the manufacturing process from grinding to the turning by tool with the tungsten carbide insert affects the predicted wear resistance of the machined functional surface.
9
Content available Improved method of gear hobbing computer aided simulation
Hrytsay Ihor, Stupnytskyy Vadym, Topchii Vladyslav
Archive of Mechanical Engineering
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2019
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Vol. LXVI, nr 4
475--494
EN
Simulation studies of the hobbing process kinematics can effectively improve the accuracy of the machined gears. The parameters of the cut-off layers constitute the basis for predicting the cutting forces and the workpiece stress-strain state. Usually applied methods for simulation of the hobbing process are based on simplified cutting schemes. Therefore, there are significant differences between the simulated parameters and the real ones. A new method of hobbing process modeling is described in the article. The proposed method is more appropriate, since the algorithm for the momentary transition surfaces formation and computer simulation of the 3D chip cutting sections are based on the results of hobbing cutting processes kinematics and on rheological analysis of the hob cutting process formation. The hobbing process is nonstationary due to the changes in the intensity of plastic strain of the material. The total cutting force is represented as a function of two time-variable parameters, such as the chip’s 3D parameters and the chip thickness ratio depending on the parameters of the machined layer.
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