Fomin Ilya

Faculty of engineering mechanics and mechanical engineering

Speciality: Technology of mechanical engineering

Theme of master's work:

"Technological support of the process of the combined functional-oriented finishing of the special metal-cutting tools"

Scientific adviser: Professor Ph.D. Mikhailov Alexander Nikolayevich

---

About author

---

Summary of research and developments

Work urgency

      Just as art is realised in products, and talent — in beauty of these products, the technics proves in products, and their quality - in aggregate properties and utility [7]. In the technician, technologies serve as means for manufacturing of products. Thus existing technologies are continuously improved and created new, providing essential increase of properties of products. It conducts to evolutionary development of technologies and technospheres as a whole.

      It is possible to notice, that the modern epoch of scientific and technical progress has made even more actual a problem of continuous development of technics, creation of essentially new technologies and technological, systems. The vector of development of a technosphere covers more and more new and perspective directions, increases capacity and intensity of scientific and technical progress. This process comprehensively extends on technologies of mechanical engineering and adjacent areas of a national economy.

      Recently, in connection with prompt development of a technosphere technologies of mechanical engineering are continuously improved, the general approaches of creation of technological processes and technologies develop widely and updated, qualitatively new technologies are created. To such technologies, technologies of a new class, function-oriented manufacturing techniques of products of mechanical engineering concern also.

      Existing technologies in the course of product manufacturing usually provide operational properties for all product or its elements. That is here, all product adapts to the maximum conditions of operation usually. It in some cases conducts to increase of the cost price of manufacturing of a product, and sometimes to decrease in operational properties. Therefore in the course of realisation of technologies it is necessary is more thin and realise technological influences at local level depending on all features of operation of functional elements of products and action of functions in nano, mikro, makro zones and product sites.

The purposes and research problems

     Work overall objective is increase of durability and wear resistance of the cutting tool on the basis of application of the combined function-oriented technology.

     For purpose achievement in work following problems are put:

1. To prove expediency of use combined function-oriented technologies as definitive method of machining of special metal-cutting tools.
2. To investigate functional zones and tool working conditions.
3. To investigate a various combination of function-oriented layers and their influence on tool work.
4. Working out of technological process of processing of the special metal-cutting tool on the basis of the combined function-oriented processing.
5. To develop recommendations for choice parametres at the combined function-oriented finishing processing.

The review of existing researches

     The given technology is new, therefore in the world there are some people which now it closely are engaged and carry out researches.

      One of the main researchers in this area is the professor of chair «Technology of mechanical engineering» of Donetsk National Technical university Mihajlov Alexander Nikolaevich. In its main work on this theme [1] it has presented bases of function-oriented technologies in mechanical engineering. Also under its management practical researches are carried out in this area.

Scientific novelty

      The scientific importance of work consists:

Definition of modes of cutting and working conditions of the tool after the combined function-oriented finishing processing.

Working out of a design procedure of parametres of operational properties: wear resistances, durabilities.

Technological support of the process of the combined functional-oriented finishing of the special metal-cutting tools

      The Function-oriented manufacturing techniques of a product of mechanical engineering [3] are the special technology which is based on function-oriented technological process and technological system. It is based on exact topological the focused realization of necessary set of algorithms of technological influence of tools and processing means in necessary nano, mikro, makro zones and sites of a product which functionally correspond to conditions of their operation in each its separate zone. Thus their kind, type, a variant, quantity, quality and algorithm of technological influence are purposefully defined, and also topological, functionally and quantitatively are guided at their realization in separate zones of a product depending on the set functional features of their operation. Application of function-oriented technologies for mechanical engineering products ¬ allows to raise as much as possible their general operational parameters at the expense of local increase in technical possibilities and properties of separate elements, surfaces and-or zones of a product depending on functional local features of their operation. Thus the products of mechanical engineering made on offered technologies, as much as possible adapt on the properties for features of their operation and show the full potential of possibilities in work.

      It is necessary to notice, that the offered new class of technologies complicates process of manufacturing of products, but as a whole provides qualitatively new set of properties and a measure of utility of products of mechanical engineering at operation. It gives the chance to raise essentially technical and economic indicators of operation and use of cars and technical systems.

      Application of the combined function-oriented technology by manufacture of metal-cutting tools occurs in some stages:

1. Shaping the metal-cutting tool on already existing technologies with reception of all necessary geometry but without definitive sharpening of a cutting edge.




Image 1 Special mills before application of coating

2. . Preparation of a surface for application of coating: there is a polishing and polishing of cutting edges of the tool
3. The focused pneumojet processing: on equipment УЗГ 4-1 there is a bombing by a powder of black silicon of cutting edges of the tool, thereby superficially strengthening them, and the necessary radius a cutting edge turns out.




Image 2 Equipment УЗГ 4-1 for the focused pneumojet processing





Image 3 Powder of carbide of silicon black

4. Ultrasonic processing of a surface: in special the equipment in a special solution occurs clearing.




Image 4 Equipment for the clearing ultrasonic.

5. Degreasing by chemical processing of a surface: the tool is processed by gasoline, acetone and spirit
6. Clearing by the decaying category in the vacuum chamber With under pressure 7•10-3Па within 10 minutes
7. Ionic bombardment in the vacuum chamber of the tool during 5 mines With under pressure 5•10-3Па
8. Tool warming up in the vacuum chamber during 5 mines With under pressure 5•10-3Па
9. Metallization of a blanket of the tool on depth 0,1мкм in the vacuum chamber during 2 mines With under pressure 3•10-3Па




Image 5 Example of metallization of products in the vacuum chamber.

(Animation is made in program Gif animator: quantity of shots - 23, quantity of cycles - 5, the size - 153Кб)

10. Application of coating on the tool in the thickness 0,7мкм in the vacuum chamber a current of 10 mines With under pressure 4•10-3Па
11. Tool cooling in the vacuum chamber within 10 minutes

      On an exit the usual metal-cutting tool, but with absolutely new qualitative properties is received in appearance.

Image 6 Special mills after application of coating.

      We promote wear resistances of the tool in 3-4 times.

      We clean microcracks on a cutting edge.

Conclusions

Nonconventional operational properties of a product and high technical and economic indicators of a product at its manufacturing and operation are provided at the expense of the following:

1. Precision maintenance of local properties of a product
2. Maintenance of properties of a product depending on features of its operation and action of operational functions
3. Realisations of group of special principles of orientation of properties of a product
4. Realisations of properties of a product on levels of depth of technology
5. Full adaptation of properties of a product at manufacturing to features of its operation in the car or technological system
6. Maintenance of the set operational potential of a product
7. Maintenance of the demanded operational potential of a product
8. Maintenance of limiting or maximum operational potential of a product
9. Realisations of high technical and economic indicators of manufacturing and product operation

Warning!!!

      Magister work is on 09.06.2010 in a working out stage, therefore changes further are possible. The definitive variant will be ready by December, 2010. In case of need for the information can address to me or my supervisor of studies.

References

1. Михайлов А.Н. Основы синтеза функционально-ориентированных технологий машиностроения. - Донецк: ДонНТУ, 20О9. - 346 с.
2. Методы поиска новых технических решений / Под ред. А.И. По-ловинкина. - Йошкар-Ола: Map. кн. изд-во, 1976. - 192 с.
3. Митрофанов СП. Групповая технология машиностроительного производства. - Л.: Машиностроение, 1983. Т. 1, - 404 с; Т. 2, - 376 с.
4. Михайлов А.Н. Некоторые аспекты создания технологий будуще¬го // Новые технологии и системы обработки в машиностроении: Тезисы докладов научно-технической конференции. - Донецк: ДонГТУ, 1994. С. 87-90.
5. Михайлов А.Н. Общий подход в создании функционально-ориентированных и интегрированных технологий машиностроения // Ма¬шиностроение и техносфера XXI века. Сборник трудов XII международной научно-технической конференции в г. Севастополе 12-17 сентября 2005 г. В 5-ти томах. - Донецк: ДонНТУ, 2005. Т. 2. С. 261-275.
6. Михайлов А.Н. Общий теоретический подход создания новых прогрессивных технологий // Прогрессивные технологии машиностроения и современность: Сб. трудов международной научно-технической конфе¬ренции. - Донецк: ДонГТУ, 1997. С 168-171.
7. Михайлов А.Н. Основные принципы и особенности синтеза функционально-ориентированных технологий машиностроения // Маши¬ностроение и техносфера XXI века. Сборник трудов XIII международной научно-технической конференции в г. Севастополе 11-16 сентября 2006 г. В 5-ти томах. - Донецк: ДонНТУ, 2006.Т. 3. С. 61-77.
8. Михайлов А.Н. Основы синтеза поточно-пространственных тех¬нологических систем непрерывного де&ствия. - Донецк: ДонНТУ, 2002. -379 с.
9. Михайлов А.Н. Основы проектирования и автоматизации производственных процессов на базе технологий непрерывного действия. - Донецк: ДонНТУ, 2006. - 421 с.
10. Михайлов А.Н. Общие особенности функционально-ориентированных технологий и принципы ориентации их технологическихвоздействий и свойств изделий // Машиностроение и техносфера XXI века.Сборник трудов XIV международной научно-технической конференции в г. Севастополе 17-22 сентября 2007 г. В 5-ти томах. - Донецк: ДонНТУ,2007. Т. 3. С. 38-52.
11. Михайлов А.Н. Перспективы создания и развития прогрессивных технологий машиностроения // Машиностроение и техносфера на рубеже XXI века: Сб. трудов международной научно-технической конференции в г. Севастополе 11-17 сентября 2000 г. - Донецк: ДонГТУ, 2000. С86-95.
12. Михайлов А.Н. Факторы эволюционного процесса развития но¬вых технологий машиностроения // Прогрессивная техника и технологии машиностроения: Тезисы докладов международной научно- технической конференции. - Донецк: ДонГТУ, 1995. С. 168-171.
13. Михайлов А.Н. Основные принципы и особенности синтеза функционально-ориентированных технологий машиностроения. // Упроч¬няющие технологии и покрытия. - М.: Машиностроение,. №2. 2007. С. 44 -53.
14. Михайлов А.Н., Михайлова Е.А.. Общая классификация вакуум¬ных ионно-плазменных покрытий на внутренних цилиндрических поверх¬ностях изделий машиностроения. // Упрочняющие технологии и покрытия. - М.: Машиностроение,. №7. 2006. С. 3 - 6.
15. Михайлов А.Н., Михайлов В.А., Михайлова Е.А. Ионно-плазменные вакуумные покрытия - основа широкого повышения качестваизделий машиностроения. // Прогрессивные технологии и системы машиностроения: Международный сб. научных трудов. - Донецк: ДонНТУ,2004. Вып. 28. С. 108-116.