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State Technical University named after NE Bauman.

(MSTU. Bauman)

A manuscript

Zaitsev Aleksei Mikhailovich

DEVELOPMENT DIRECTION OF INCREASING EFFICIENCY

Technological preparation of production

Parts and assemblies rocket and space technology

05.02.07- Technology and equipment for mechanical and physical-technical

processing

05.02.08- Engineering Technology

Thesis for the degree of

Candidate of Technical Sciences

Scientific adviser -

Doctor of Technical Sciences, Associate Professor

SV Rude

Moscow 2016
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TABLE OF CONTENTS

P.

LIST OF ABBREVIATIONS .......................................... .. 5

INTRODUCTION .............................................................................. ... 7

CHAPTER 1. THE PROBLEM OF EFFICIENCY

PREPARATION OF KEY TECHNOLOGY IN

PRODUCTION SPACESHIP

NEW GENERATION eleven

1.1. Identify key areas of the CCI and the ways to increase
eleven
the effectiveness of their training. ...................................................... ..

1.2. State of automation components CCI CT ............ .. ............... ... 20

1.3. application additive technologies in the aerospace

industry .................................................................................... .. 21

1.4. The use and characteristics of manufacturing a wafer structure

shell ..................................................................... .. ............. 24

1.5. The analysis of existing research and practical solutions


29
milling body parts from aluminum alloys ..........

1.5.1. Analysis of calculation of the available options and the contact forces

Pressure to eliminate strain when milling housing


31
details. ....................................................................................

1.5.2. Application of the method of finite elements for impact assessment


33
power factor on the piece by milling. ................................. ..

1.6. The purpose and objectives ............................................................. 34

Chapter 2. ENSURING EFFICIENCY THROUGH CCI

Introduction of advanced technologies. ......... 37

2.1. The use of information technology for automation

CCI .................................................................. processes. 37


3

P.

2.1.1. Development of parallel loop through CCI aerospace hardware. 37

2.1.2. Developing negotiation process algorithm

documentation electronically .......................................... ... 41

2.2. The use of additive technology to reduce the complexity of

Design STO ............................................................... .. 49

CHAPTER 3. OPTIMIZATION OF PREPARATION

CASE perspective products RKT With EKR .. 58

3.1. constructive and technological especially housing

prospective products with EKR .............................................. 58

3.2. Study design processability wafer shell ... 60

3.3. Choice of machining strategies typical element wafer

structure ........................................................................ 64

3.4. Optimization of treatment regimes in order to avoid deformation

waffle design elements with the specified parameters. ...... .. 72

3.4.1. Calculation of forces and the contact loads when milling

end mills aluminum alloy from specified

performance ............................................................ ...... 73

3.4.2. Development Program (Trailer_mill) and the calculation of the cutting forces,

operating elements on the sleeve with a waffle structure ...... 80

3.5. Methods of optimization processing technology with shell

waffle design ...................................................... ... 91

CHAPTER 4. EXPERIMENTAL INVESTIGATIONS

workability HIGH

ALUMINUM ALLOYS .................................... 94

4.1. Research objectives and indicators workability ..................... 94


4

P.

4.2. Study of the dependence of roughness on the cutting mode ... ....... 95

4.2.1 Equipment and tools for experimentation ... .. 95

4.2.2 The practical results of the processing end mills ... .. 97

4.2.3 Dependence of performance, power, torque

........................................................................... moment .. 103

4.3. machinability study on cutting force ... ... ....... ......... 105

4.4. Investigation resistance carbide cutters and determination


110
the number of mills for processing of the new ship's hull .... ...... ........

CHAPTER 5. APPROVAL OF THE WORK ..................... 116

5.1. Production verification algorithm and approval

TD electronically ... .. ................................................... ... 116

5.2. Experimental verification of the optimization of machining strategies

EKR pocket ..................................................................... .. 118

5.3. experimental inspection received dependency

roughness of processing modes ....................................... 119

5.3.1 Detail "waffle design element" ................................. 119

5.3.2 Detail "Frame" ............................................................ .......... 122

5.4. Production and experimental verification of the results

for example, the manufacture of the housing part segment EKR

promising products ................................................ ........................... 125

EXECUTIVE SUMMARY ..................................................................... 132

BIBLIOGRAPHY ................................. .................................... 134

ATTACHMENT ..................... ...... ................................................ 142


5

LIST OF ABBREVIATIONS

CJSC "ZEM" RKK "Energy" - Experimental Engineering Plant

Rocket and Space Corporation "Energia". Korolev

CCI - technological preparation of production

RKT - Rocket and space equipment

ISS - International Space Station

NEM - Research and Energy Module

TEM - transport and energy module

CNC - computer numerical control

HRC - a thermal barrier coating

CD - design documentation

TD - technical documentation

STO - tools, jigs and fixtures

TP - technological processes

SLS - Selective laser sintering

OAO - Open Joint Stock Company

NGOs - Research and Production Association

EKR - waffle shell design

CB - Building Design Bureau

RN - booster

OK - Orbiter

PTK NP - a new generation of manned transport ship

QC - spaceship

FEM - Finite Element Method

CAD - computer-aided design

PDM-System - Product Data Management (Data Management System

product)

DSE - parts and assembly units

BTK - Technical Control Bureau


6

USP - prefabricated universal device

EMR - electronic appliance model

KIM - control-measuring machine

Russian Federation - Russian Federation

TC - technological system

OC - machining center

PC - Personal electronic computer


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INTRODUCTION

Relevance of the work. The global market for space products

characterized by stable competition between the main producers

rocket and space technology. Therefore, the competitiveness of

Russian rocket and space industry largely

It depends on the decision of the technological base of modernization tasks, methods and

resources planning and management.

Relevance of the work defines the tasks for the next 5

years before the JSC "ZEM" RKK "Energy" as a parent company for

CT manufacturing products. These tasks, in addition to serial production

transport and manned spacecraft and upper stages,

include (see Figure below..):

- manufacturing by 2021 of a new manned transport spacecraft

generation (PTK NP);


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- manufacturing 2018 NEM ISS;

- manufacturing by 2021 TEM "tug" and autonomous

process module;

- design and manufacture of satellites and space objects

various applications.

a new generation of spacecraft and other promising

RKT products, will have a completely new design solutions,

such as the wafer housing shell design, application

high-strength aluminum alloys. Conduct technical training

production of products is expected in a single information field

using 3-D modeling in CAD.

The need to ensure strict deadlines for the preparation of production

and manufacture of CT in combination with a new form factor requires

utilization effective organizational and technical solutions and

introduction of advanced technologies.

Since the production of aerospace hardware is a single or

small-scale, in the general cycle of product development a significant part

It takes production planning.

Therefore, the work, aimed at improving the efficiency of

technological preparation of production of aerospace hardware is up to date.

Research methods.

The work includes the theoretical and experimental methods

research and computer modeling. Used the main provisions

mechanical engineering, cutting theory, mathematical methods

modeling and programming. Investigation deformation shell with

waffle structure carried on a computer based on a FEM

obtained using the calculated and experimental data.

experimental research workability high

aluminum alloys, and the influence of cutting conditions on quality indicators

processed surfaces formed on both experimental setups,


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and in the actual production conditions in the processing of the body segment

IN TO.

Scientific novelty:

1. The technique of CCI complex technical object -

the housing part with SAI comprising CCI management, analysis

technological design, the choice of optimal treatment strategies

Model element of EKR, optimize treatment regimes based

EKR cells exceptions deformation.

2. It proved the possibility of the use of additive technologies

improve the efficiency of design stations.

3. New results in the cutting of high-strength

aluminum alloys and roughness values when cutting forces

milling, experimental data on tool life.

4. The efficiency of the interaction of several engineering teams

in a variety of CAD and PDM-system with electronic approval TD.

The practical value of work lies in the fact that:

Developed and implemented a matching algorithm TD electronically.

Obtained in practical depending milling

high-strength aluminum alloys.

Developed and approved instructions for the CCI components with VKO, the main

position confirmed by practical testing in the development of

technology segment manufacturing process of a new body

ship and other standard parts.

designed beam production technology pipelines

using the SLS method.

Implementation of the results. The results are implemented in

developed and implemented into production processes

machining a new ship segment and pipe assembly

CJSC "ZEM" RKK "Energy", and harmonization TD machining

carried out by an algorithm developed in this paper.


10

Obtained in working out recommendations for manufacturability,

Strategies and insertion processing, and cutting modes in the manufacture

parts with EKO used in the issued and implemented in production at

CJSC "MEM" technological instruction.


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CHAPTER 1. THE PROBLEM OF EFFICIENCY IN CCI


KEY AREAS FOR MANUFACTURE
ADVANCED EQUIPMENT CT

1.1. Identify key trends and CCI

ways to improve the effectiveness of their training

In order to solve the problems of modernization of technological base, methods and

The means of production planning and control in the production of new

aerospace hardware necessary to determine the most critical and time-consuming

trends in the production of X-ray CT and the corresponding technology,

which will be called the key, as well as state and ways to improve

CCI effectiveness in key areas in the framework of modernization

means of production management.

Production planning - a set of measures,

providing the technological readiness of production, which

complete sets determined by the presence at the plant design and

technological documentation and technological equipment,

needed for the production of products with established technical and economic

performance in a given volume [1].

CCI will analyze the main areas to identify key

technologies in spacecraft manufacture of new generation on the basis of

structure complexity existing manned vehicle, and the result

We will adjust based on the design features of the new ship and

technological tasks assigned to the solution in its manufacturing.

Consider the complexity of the structure of the manned spacecraft "Soyuz"

(Fig. 1.1). Based on the analysis, one can identify the major

technology, representing the highest labor intensity. This is primarily

machining technology, which occupy almost a quarter

complexity of products (23.3%), and include the turning operation (including

Lathe carousel and boring processing), milling (in all


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types of milling equipment, including special machines small

Mechanization) and processing CNC different types (turning,

milling).

It should be noted that over the last 8 years with a continuous input in

new equipment, CNC machining to share this type of

equipment is substantially increased.

The complexity of the following technologies are technologies

Test occupying about 19% of the complexity of manufacturing the product.

This type of technology has a number of directions, such as

pnevmogidroispytaniya, testing in a cryogenic environment, vacuum tests,

Vibration test, dynamic and static tests, etc.

Tests are carried out for both individual parts and for components and manufacturing

Overall in various stages of readiness.

Fig. 1.1. The structure of the complexity of manned spacecraft

More than 15% of the complexity of the product is occupied at the moment

for tool operation. It is a wide range of technologies, including the

as the manual work using the screwdriving tool and metalwork

working with a variety of equipment and tools, such as:

drilling machines, Pneumodrill, bending equipment, locksmithing


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tools, etc. Often, due to the use of plumbing technology

imperfection of other technologies in both individual workshop and the

enterprise as a whole. At the same time, in many cases, metalwork technology

and manual labor proved to be effective and appropriate, if

take into account the fact that the production of aerospace hardware mainly

single or small-scale.

Electrical technologies represent almost 14% of the total

the complexity of ship manufacturing. This type of technology is used in

shops instrument manufacture, as well as in the main assembly of products shops.

Determinant of the effectiveness of these technologies is labor

electrician and his qualifications.

The next group of technologies constituting about 8% of the total

the complexity, make assembly, welding and riveting technology.

These technologies are characterized by the use of special equipment,

develops and produces in most cases for each

new product individually. This is primarily stacker equipment for

assembly, riveting equipment enclosures, as well as the large special

accessories for welding systems required for deployment, consolidation

parts of the housing and traffic along the seam of the welding head.

Used assembly and welding technologies are constantly being upgraded and

improved based on the results. However, the design features

Space a new generation of the hull, as well as some other

promising products, where it is supposed to order more welding

thickness of aluminum alloys with high strength in combination with

increased requirements for weld strength, requires the introduction of

modern welding techniques, such as friction stir welding.

Finally, a group of extreme technology, which occupies a substantial part of

total workload (5.3%) are thermal barrier coating technology

coatings.
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The spacecraft during descent from orbit, passing through dense layers

atmosphere, is subjected to strong heat. For guard

of the vehicle from damage and destruction due to this influence, the outside

surface lander protected by the application of HRC.

HRC technology application has its own specificity: the lander

placed in a special chamber, called a digester, where the layers

Several different coatings applied at a certain temperature and after

specified intervals.

If we consider the technologies identified in relation to the

production of advanced products, such as spacecraft

the new generation, it is necessary to highlight some of the technologies that

inevitably require improved efficiency.

Given the changed dimensions and constructive new ship can

say with certainty that ensure efficiency technologies

mechanical processing required conduct preliminary

theoretical and practical research. introduction of

large equipment for machining, further introduction

turning and milling machining centers necessary for the development of

huge nomenclature of the new ship parts. The use of high-strength

aluminum alloys in the housing parts and the details of the power set requires

research in the workability of these alloys.

The use of a wafer shell design of the new ship's hull makes

necessary to analyze the workability of such a construction.

It is necessary to take into account the fact that the complexity of the mechanical structure

processing change significantly towards increasing the share of processing

CNC equipment, a significant part of the complexity of processing locksmith

canceled due to the use of modern equipment, tools and

technology.

One of the main technologies for the production of the ship, of course,

It will test technologies. Part of the work in this direction is possible


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spending on the existing modernized equipment. At present,

time held a deep modernization of cryogenic test stand

Shar cylinders upgraded bronekabiny for strength testing

reinforcement nodes and pnevmopulty and vacuum chambers. For

pnevmogidroispytany new ship at different stages of readiness

necessary to upgrade the appropriate size of the vacuum chamber,

whereby the test current generation of ships is conducted

repair and modernization of smaller size vacuum chamber. In this way,

for a new ship trials should continue

modernization of equipment and testing technology will remain a key

direction with the level of complexity of 18-20%.

Through the use of modern technologies of mechanical

machining, electrical discharge machining, waterjet cutting, etc.

It is expected to significantly decrease the complexity of plumbing work, up to 8-10%.

In the manufacture of a new generation of spacecraft application locksmith processing

it is only necessary in cases where it is appropriate and effective

based on small-scale release of spacecraft. Locksmith

methods of processing are substantially independent of automation, modernization

or any increase in efficiency, and in view of the introduction of

advanced equipment and technology in the manufacture of a new ship

locksmith generation technology is not the key focus.

The volume of electrical work in the manufacture of a new ship

It is expected at the same level 14% of the total complexity of the product.

Technology of electrical work as little susceptible to automation

and modernization and are largely dependent on artist development.

Due to the use of new manufacturing space under linings

a new generation of spacecraft is expected to reduce the length of the welds

up to 5 times. Overall, therefore, it is expected to reduce the complexity of assembling and

welding operations. However, in the design of the new ship's hull

provided high demands on the strength of welds and


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the need for welding of large metal thicknesses (welding plates 30mm).

Therefore it is necessary the use of a new type in the manufacture of the housing

Welding - friction stir welding. To implement this process,

required priobrenie and development of large-scale equipment, and

design and manufacture of equipment essentially new structural elements,

to provide the desired rigidity of the fixing parts to be welded. Also

due to changes in the size of the new ship, compared with the ship

"Union" need to design and manufacture a significant

the amount of tooling jig. Changing the configuration of the pipeline

systems makes it necessary to design new devices for

assembling and welding of separate pipelines and pipelines beams. therefore

to improve the efficiency of production preparation in terms of

tooling design and development of technological processes of assemblage-

Welding is relevant and implemented through automation

process design CD and TD.

To solve the problem of increase of efficiency necessary to determine

the key areas of advanced products CCI CT (Fig. 1.2).

Fig. 1.2. The direction of technological preparation of production


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As shown by the analysis of individual technologies in complexity

production of the main products of the enterprise base, technologies

machining, assembly (welding) and add up to test

More than 70% of the total complexity of the product.

The volume of technological training in these areas more

different, but the trends are similar. In addition to these key

trends in the manufacture of new products RKT large amount of CCI

comprise processes for mining technology and technological

planning and design of technological equipment,

the volume of which in the manufacture of products already mastered much lower. AT

Currently, the company already produces the upgraded and new

RKT products, spending CCI forces a certain number of experts in

lines (Table 1).

Based on the sufficiency of the condition number of specialists (engineers

technologists and engineers design of technological equipment

(SR)), which is generally at the moment is urgent, we hold

Analysis of the amounts (Table 1) and define the direction key CCI

in the manufacture of advanced aerospace hardware.

Table 1.

The ratio of specialists in the fields at the CCI

number Direction %
1 TP machining 32
2 TP assembly 19
3 design STO 16
4 TP test 13
5 technology planning 4
6 Testing on manufacturability 4
7 Other 12
in total 100

The main part of the overall complexity of the process make CCI

preparation of machining processes, assembly, tests, and


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design and development of stations on manufacturability, which together

up more than 80% of the complexity of the preparation of the product (Fig. 1.3).

There is every reason to believe that this situation will continue in general and

manufacture of a new ship.

Thus, to improve the efficiency of the new ship at CCI

CJSC "MEM" should work to improve the effectiveness of training

5 key areas - machining, assembly, testing, design

tooling and testing of manufacturability, as well as on the introduction of

advanced information and additive technologies that can

ensure the efficiency of all key areas of the CCI.

Fig. 1.3. The proportion of individual components in the total workload

technological preparation of spacecraft production

The main ways of increasing the efficiency of the CCI a new ship

look at two:

- automation of individual processes and CCI as a whole;

- the introduction of advanced equipment and technology.

Improving the efficiency of the CCI by automating processes - it

known path that has proved its relevance and necessity of having

with typical problems and shortcomings.


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Thus, automation of technological processes and the development of control programs,

rigging, route-razrezochnyh statements and other local processes

using modern CAD dramatically reduces the complexity of these

tasks. CCI Automation of the entire process using PDM-systems

together with the automation process solves the problem of local

increase the efficiency of interaction between different engineering groups for

by parallel work on the project and the exchange of information at work

a single space. These include the development of processes of KD and TD,

working out on the manufacturability, planning, design service,

coordination, approval and archiving of documents in electronic form.

However, improving the efficiency of the CCI by automating much

It depends on several factors. First, it is the ability of staff

to master the current to a predetermined level, often enough

complex software products. Second, no less important and complex

task is to set up the CAD and PDM-systems in accordance with

CCI in the enterprise features and normative documentation at

conducting CCI. Only after these issues can be expected

CCI decrease labor intensity.

introduction of advanced equipment and technology It requires

substantial funds, has specific requirements for the qualification

personnel. However, from the point of view of the CCI implementation of new equipment,

in addition to the new technological possibilities of production, could give

a significant reduction in the complexity of the CCI. For example, the presence of 5-

axis machining centers, EDM and CNC

etc. It can greatly simplify the technology and manufacturing parts. A

the use of additive technology in manufacturing can reduce

the complexity of CCI products in several areas, such as

machining, assembly and design of stations.


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1.2. State of automation products CCI CT

One of the major limitations is the duration of the creation cycle

RKT products from the time of conclusion of the contract until delivery of the object in orbit.

Since the production of X-ray CT is a single, in the general cycle of creation

product occupies a significant portion of the design, construction

product and production planning. These steps, as well as all

life cycle of products, develop in the conditions of today

automation.

Traditional in a local automation serial

design and technological preparation cycle is shown in Fig. 1.4. is he

responsible standardized procedures developed under the "paper"

technologies.

Fig. 1.4. Sequential loop design and technological preparation

production of goods
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Conventionally, serial production cycle can be divided into 9

basic steps:

- product design;

- simulation products and engineering calculations;

- development and production of design documentation;

- technology planning and development of manufacturability;

- development of technological processes of manufacturing parts;

- design and manufacture SRT;

- the development of control programs;

- rationing;

- Product manufacturing and control.

The sequential cycle begins the next stage of operation just

after completion of the previous [2] and the corresponding clearance

Documents in paper form.

Benefits of such a route are that the data exchange via

Paper documents issued in the prescribed manner the standards,

It enables automation of each step of the process

preparation of production in any place convenient for this software product,

without being attached to a different phase of the automation.

The main disadvantages are the duration of the cycle, where almost every

stage begins after the end of the previous one, as well as the re-establishment of

electronic data, previously created in the previous steps.

1.3. The use of additive technologies in the aerospace industry

Additive Technology - a relatively new type of technology,

under development in the second half of the twentieth century, and actively

applied in various industries, particularly in industry and

engineering, only the last twenty years, when the first

the addition of the machine. The basic principle is that the product
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It is created by adding the layered material different

methods such as spraying or fusing a powder, liquid

polymer or composite material.

Currently additive technologies are widely

distribution and continue to flourish and take root. it

not surprising, since these technologies allow to manufacture products that

impossible to get on the classical technology, and in some cases

use additive technology simply much more efficient. After all, they

allow to produce details of products, tools, and even the whole assembly.

One of the most common techniques related to

additive technology is the selective laser sintering method

(Fig. 1.5).

This method is widely used due to the high

speed and accuracy of the products as well as the possibility of manufacturing

articles made of various materials, including metals.

Fig. 1.5. Schematic diagram of the process of making an article sample [3]
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However, this method, like other methods related to

additive technology, have questions, which are currently not

resolved and put in their application to certain restrictions. In-

First, it is a question of producing a given material, and secondly -

This purchase material powder in the required amount. Nomenclature

powders produced is very limited, all their compositions correspond

European regulations and standards, and predetermined manufacturing powder

composition makes sense for large volumes. Third - not investigated before

end questions of durability and tightness of the resulting articles. It is not

should not forget that the cost of manufacturing parts by SLS yet

It is quite high, and depending on the complexity of the product question

the effectiveness of this method require separate consideration. All

These questions are currently impose significant restrictions on

the use of additive technologies in the manufacture of rocket and space

technology. The wide range of materials of construction for

Details CT does not correspond to the composition of the powders produced in the aggregate

with high complexity parts replacement material in the product, and lack

information about the properties of the resulting material at the moment do not give

the ability to produce parts directly via CT

additive technology. This requires an adjustment CD, standards and

conduct additional confirmatory tests.

Nevertheless, there is a wide range of possible applications of additive

technologies in the production of X-ray CT, such as manufacturing equipment,

tool, layout and prototyping.

Thus the basic aerospace giants such as Pratt & Witney, GE

Aviation, EADS, Boeing and others are already widely used additive

technology for the manufacture of parts of their products and in their manufacture,

Producing this way tens of thousands of parts and components. the beginning

manufacture of parts by SLS and Russian companies, such as

JSC, JSC "NPO Saturn" "Aircraft Engine", AKB "Anchor" (Fig. 1.6). [4]
24

Therefore, the additive technology is undoubtedly a promising

direction, including in the space industry, and requires

prompt adaptation and implementation in production.

Fig. 1.6. Examples of the parts produced by the method for SLS

Russian companies

1.4. The use and manufacturing features EKR

Shell with wafer design were widely

spread in the rocket and space technology. The first industrial

the use of such shells in the country recorded in the early 1960s

years when in CB "Salute" started production of missiles UR-200, UR-500 and Ur

100.

In the process of designing the tanks of these missiles for the first time in the country

proposed and implemented a tank shell design with the grid

reinforcing ribs, which received subsequently a wide circulation in

rocket called waffle [5].

Despite the significantly greater labor input in the manufacture of

Compared with smooth shells, shell with less waffle structure

sensitive to local dents depth to half the height

wafer panels and have a considerably greater bearing capacity

under axial compression than equal by weight to them smooth [6]. A construction with
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minimum weight and maximum strength characteristics

particularly relevant for rocket and space technology, where important and

roads every kilogram of launching the payload into orbit.

Fuel tank rocket consists of several cylindrical

sectors waffle background, welded together in a single cylinder.

Sector were made mostly of slab AMg6n, EKR pockets

obtained by chemical milling or machining

(Table 2).

The use of a waffle design shell fuel tanks

and continued on. Besides SD-200 (diameter: 3000 mm, sheet thickness of 16 mm,

pocket size 70h70mm), such a tank design has been applied in

Further rocket "Proton" created on the basis of SD-500 (diameter 4100mm,

sheet thickness of 16 mm, pocket size 70h70mm), SD-100 (diameter 2500mm).

In the 70's fuel tanks with wafer design shell

used in RN "Zenith" (3900mm diameter, 30 mm in sheet thickness), and after

10 years in "Energia" (8000 mm diameter, plate thickness 45 mm).

Shells with wafer structure used in rocket R-27

US fuel compartment PH SaturnV (S-IVB stage). currently

time perspective LV "Angara" fuel tanks also have the

design (diameter: 2900 mm, the plate thickness 14 mm).

In addition to fuel tanks missiles, there are other applications with facts shells

waffle design. In OK "Buran" cockpit module housing (Fig. 1.7)

It consists of a shell, six frames, the front and rear ends, upper and

Floor and lower panels assembled wafer structure manufactured

milling the aluminum alloy plate and connected to an automatic

welding [7].

Wing Tu-144 and consists of a core and has detachable parts

box-like structure with a covering power as a loaded

milled oversized panels waffle structure of

high-strength aluminum alloys [8].


26

Table 2.

Methods for producing wafer shells with their construction and applicability

ed in exactly
Note
method number st Experience of Material

Low accuracy, high


cost of the stamp,
Stamping 1 3mm - -
complicated
technology

Rocket R-27,
AMg6
housing
1-2 insufficient
2 Chemical PH Saturn V, step
milling mm Al. Alloy accuracy
S-IVB, fuel
2914-T6
compartment

The Tu-144,
wing

"Proton-K"
"Energy",
AMg6 (n)
Machining "Zenith", the fuel

(frezerova- 0.2 tanks


3
mm OK "Buran", the

of) module housing AMg6

cabin

Spacecraft "Orion"

housing

PTK NP, housing 01570S

Low relative performance,


Elektroerozi-
0.05 high cost
4 onnaya - -
mm
processing
tool
27

Fig. 1.7. Housing cockpit module OK "Buran" is made up of a waffle panels


design

Currently, topical was the question of the use of the shell with

waffle structure in housings promising vehicles and

manned spacecraft. Russia (Fig. 1.8, the PTC-NP) and the US (Fig.

1.9 QC "Orion") are developing spaceships, which are the body

IN TO.

Application wafer shells is limited, on the one hand,

technological capabilities, on the other - the mechanical limit

properties of the material used. With a relatively small loads, and

also at small dimensions of the shell calculated dimensions (thickness of the wall,

width edges) can turn less than a technological

limit level of which depends on the material used, the process

manufacturing equipment and production culture, i.e. fulfillment of such

sizes may be impossible to [9].

In the domestic and foreign literature are

Recommendations of a general nature for machining parts with

SAI, in particular milling pockets modeling process and

calculation parameters [10-14].


28

Fig. 1.8. Layout Russian spacecraft of new generation: at

background on the right housing segment with EKR

Fig. 1.9. Housing with EKR American perspective spacecraft "Orion"


29

1.5. The analysis of existing research and practical solutions

milling body parts from aluminum alloys

In the manufacture of body parts milling CT

It is the main processing. As can be seen from the classifier

Machining parts CT (Fig. 1.10) [15], the first five items

groups as well as groups of 9 are body parts. case details

CT may have a different shape and size, and the share of milling

processing a total complexity of their production is about 70%.

It should be noted that the vast majority of case

RKT parts made of aluminum alloys such as AMg6 AK6,

AK8 because These alloys have a high mass-strength properties,

which is very important for space objects, as there is always a limit

possible elimination of the power of the carrier rocket.

Fig. 1.10. Qualifier CT and share machining parts

milling a total complexity of manufacturing parts


thirty

With the same purpose, the housing parts are designed maximum CT

lightweight, but without compromising strength and technologically, it looks as

different types of pockets, slides, ledges.

In general, aluminum alloys respond well to mechanical

treatment, there are some recommendations, in particular on the cutting speed

Depending on the alloy [16] as well as Treatment regimes in catalogs of firms-

tool manufacturers.

Fig. 1.11. Examples of body parts CT.

However, no data on the cutting forces which occur during handling

high-strength aluminum alloy, which is very important in the processing of

thin-walled housing parts.

Due to the above features, body parts often CT

may have a complex configuration, deep pockets and thin walls (Fig.

1.11), which can cause stiffness limited technological

design.

These circumstances impose additional requirements on

manufacturing and restrictions on the modes of cutting technology.


31

1.5.1. Analysis of calculation of the available options and the contact forces

Pressure to eliminate strain when milling housing

parts

Housing parts made of aluminum alloys are widely

application as a part of aviation and aerospace technology. AT

According to its purpose, these parts have their own design

features. In particular, the housing parts can be characterized

considerable dimensions and comprise a large number of

pockets to reduce the total weight. The processing of such pockets

It carried out on multi-axis machine tools carbide integral

or teams of end mills. when a high-performance

milling the housing parts possible deformation of the walls and bottom of pocket

and technological measures are available to reduce the strain. [12]

These activities, for example, relates to control of the cutting force during

milling, and establish a connection with the forces of milling resistance

instrument and output indicators treatment [13].

A promising direction is to calculate the force and contact

pressure, allowing at the stage of technological preparation of production

to define the strategy, the consistency and the operating conditions

milling precluding deformation of the walls and bottom of the pockets. A number of studies

foreign authors are methods for calculating cutting forces, for example,

in [14, 17]. A generalization of these techniques is to model

tangential (1.1) and radial (1.2) constituting a power [18]:


x
FK
t
ah Ktp a, te p (1.1)

x
FK
r
ah Krpa, re p (1.2)

Where ap - the axial depth;

h - the thickness of the shear layer;

x - exponent set experimentally;

t
. te- .coefficients
KKKK r
. Re are established experimentally.
32

The national reference literature power output

or milling are given in a tabular form, or the degree of the equation

[19, 20]. The main drawback of these sources is the fact that these

data and values of the constants of exponents and correction

ratios do not reflect the current range of regime parameters,

corresponding carbide end milling conditions

cutters workpieces of aluminum alloy.

Widely used in recent years is a technique for calculating the forces

Cutting through specific effect [21]. According to this method, any kind of

processing blade tangential component of the cutting force (1.3) can

It is defined as
(1 ) m
F cbhK K bhc k cK,
f eleven f
(1.3)

Where b - the width of the shear layer;

h - the thickness of the shear layer;

K f - correction factor;

k c11 - specific force per unit area of the cut;

m - exponent.

Values of the specific force and the exponent given to groups

processed materials [21].

The disadvantage of the expressions (1.1), (1.2), (1.3), as well as the degree of the equation

to calculate the forces in milling [20] is that they reflect and

summarize the results of the experimental data and are valid for

specific machining conditions.

Thus, it is necessary to calculate the forces and contact pressures

for subsequent analysis of strain and stress on the pocket surfaces

large housing part at its end-milling cutter and

Modes for validating and processing conditions.


33

1.5.2. Application of the method of finite elements for impact assessment

power factor on the piece milling

At this point in time to solve a wide range of technical

tasks is widely used so-called finite element method,

which is incorporated in the basis of many software products. With development

computing resources and performance capabilities of the method

constantly expanding, and also expanding the field of tasks. AT

currently offered to a large number of finite realizations

elements in the modeling diffusion, thermal conductivity,

hydrodynamics, mechanics, electrodynamics and others.

Method end elements - numerical method

solutions of differential equations with partial derivatives, a

also integral equations, arising from the decision of tasks

Applied Physics. The method consists in the fact that the area (one-, two-,

or three-dimensional) occupied by the structure is partitioned into a number of

small but finite size of subdomains, which are called

finite elements, and the breakdown process - sampled. As a result,

breakdown of an arbitrary shape area is a grid with a finite

number of elements. In this case, the grid can be made more rare in those places,

where the calculation accuracy is not critical, which can significantly reduce the amount of

calculation.

For a long time widespread FEM hampered by a lack

automatic partitioning algorithms region on the "almost equilateral"

triangles (the error, depending on the variation of the method, back

proportional to the sine or the most severe, or very obtuse angle

partition). However, this problem was successfully solved (algorithms

based on Delaunay triangulation), which made it possible to create a completely

Automatic finite-element CAD.

In engineering, finite element method is widely used for

assess the strength of structures in their design. However, the application


34

this method for determining the process conditions in the manufacture

various designs, particularly when machining

thin-walled parts, and also to evaluate the accuracy of the milling treatment on

stage of technological preparation of production, started relatively

recently.

In [22], the authors using a finite element method (and

software complex Ansys), as well as using the empirical expression

[23], estimates the amount of elastic deformation cutter from contacting the workpiece

in process of treatment. The main result of this work - equation (1.4)

binding processing modes with the magnitude of the elastic wrung cutter:

q 1
f Fr.
(1.4)
x y u
0.8 * 10 * cp
* * t* * * SB z DK * m
*K w
w id article
./ .

Such a result may be useful to assign modes technologist

processing providing predetermined design accuracy and sensitive

mills settlement deformation. However, when this is required for each

the specific type of cutter and perfect rod holding finite

Elemental analysis calculated with the load. In addition, you should not

forget that the empirical expression [23] is only suitable for calculating at

milling force and is not suitable for the calculation at high-speed

milling, where the cutting width has a small value.

In this case, in this article we are talking about the processing of the pocket wall

an end mill, and the authors considered only the deformation of the cutter,

Taking a pocket wall absolutely rigid. It should be noted that

analogously can estimate deformation pocket wall if it

will about thin by introducing additional

pliability wall coefficients.

1.6. Purpose and objectives

From the above analysis of research and practical solutions

by technological preparation of production, milling


35

aluminum alloys and fabrication of parts with wafer shells

design implies that there is a large scientific and practical material

based recommendations in these areas. However, automation

technological preparation of production are often heavily dependent on

businesses, where it is held, and, in spite of the general similarity, the process

automation of a specific enterprise may vary significantly due to

features production structure and historically

circumstances, and therefore requires an individual approach. insufficiently

attention paid to analysis of treatment efficacy aluminum alloys and

choice of methods increase the efficiency of machining due

their relatively good processability, with any information

for workability high strength aluminum alloy substantially

absent. No information on the manufacturability evaluation procedure, and

recommendations for optimization of modes and sophisticated machining strategies

Technical Object - shell with a waffle structure.

Thus, the aim is to minimize the complexity of operation

technological preparation of production in key areas

manufacturing parts and assemblies perspective articles CT.

In accordance with the purpose of the work the following tasks have been set:

1. Identify key CCI and ways to improve the direction of its

efficiency in the production of advanced aerospace hardware.

2. Improve the efficiency of the CCI by automating the development and

harmonization of technical documentation.

3. Improve the efficiency of the Chamber of Commerce in design tools

technological equipment (SRT) by applying additive

technology.

4. To develop a technique for the manufacture of CCI

oversized body parts with EKR.

5. Determine the roughness, cutting force and tool life

during milling promising high strength aluminum alloys.


36

6. Determine the permissible cutting conditions when milling for

eliminate deformation bottom pocket EKR bulky housing.


37

Chapter 2. ENSURING EFFICIENCY THROUGH CCI


Introduction of advanced technologies

2.1. Application of information technology to automate the CCI

2.1.1. Development of parallel loop through CCI CT products

As mentioned in Chapter 1, the production of X-ray CT is a single and

in the general cycle of the product development process takes a significant part

pre-production. A promising way to increase

effectiveness of CCI is the implementation, use and permanent

development support at the current level of advanced information

technology, which primarily include CAD and PDM-system.

Efficacy is determined by the ability of using CAD

reduce the time of design and technological preparation of production.

To determine the effect of CAD TP mechanism to reduce the time

preproduction experimental work was carried out with

using techniques of parallel through-cycle compared with

the traditional sequence (Fig. 1.4).

When implementing a parallel loop-through automation

the design process, the establishment of control programs

for CNC machine tools is an integral part of a complete automation

process design and product design and process

documentation, Design and Technology workflow and

electronic archiving [24,25]. The task of the experimental

work was to determine how the overall automation allows

shorten the cycle of technological preparation of production by

parallelism procedures when operating in a single information field

by PDM-system, where access to the product at any stage of development

It may be carried out simultaneously in several engineering groups:


38

designers, designers, engineers from different departments. Second

task was to check the spread of the hypothesis that the effect on

Automation is achieved when all aspects of engineering work at

design and technological preparation of production in the through

parallel loop automated using any one

system. The main argument in favor of this statement

It puts forward that the costs of the loss of information when pairing

various design automation systems immeasurably greater than

the costs caused by the weakness of any functions in any given system.

To evaluate the effectiveness of the through parallel loop when

design and technological preparation of production in comparison with

consistent at application exactly one system

computer-aided design, passing circuit composed

traditional sequential cycle design and technological

preproduction and determined its stages (Fig. 1.4).

The sequential cycle begins the next stage of operation just

after completion of the previous [26] and the corresponding clearance

Documents in paper form.

Benefits of such a route are that the data exchange via

Paper documents issued in the prescribed manner the standards,

It enables automation of each step of the process

preparation of production in any place convenient for this software product,

without being attached to a different phase of the automation.

The main disadvantages are the duration of the cycle, where almost every

stage begins after the end of the previous one, as well as the re-establishment of

electronic data, previously created in the previous steps.

When working within the parallel loop-through (Fig. 2.1) at the expense of

work in a unified information environment in the first stage during the

design and development of CD products have the opportunity to parallel

engaged in working off of manufacturability, as well as technological


39

scheduling to the time of closure of the product development in the form of 3-D

assembly model was released products manufacturing route and, thus,

All information has been prepared for the transition to the second stage through

parallel loop.

Parallel operation is performed at the second stage design and

technology groups in a single information environment: Based on the 3-D model

Designer products involved in design drawings for production and

control products, as well as CCI continues to develop technological

documentation, design and manufacture of special relativity.

Figure 2.1. Pass-through parallel product creation cycle

Thus, the time of transition to the third stage through

parallel loop, fully carried out, and technological training

released product drawings, which allows you to make the manufacture and

Further inspection of the product.


40

Application through the parallel loop when the Design

technological preparation of the phases allowed to conduct in parallel,

significantly increased the efficiency of design and technology

training in general and technological preparation of production in particular.

The diagram (Fig. 2.2) shows the reduction of the period of the Design

technological preparation of production through the use of pass-through

parallel loop.

Fig. 2.2. Graph comparing successive stages and through

parallel cycles of production preparation products

The results of experimental studies also show that, despite the

possibility of loss of the data part by using different CAD,

using different systems is justified because none of the relevant


41

automated systems design not has all

capabilities required to create the product.

Significantly improved the efficiency of use through

parallel loop pre-production ability to exchange data

between CAD Pro / Engineer CAD ADEM in a single information

PDM-environment system Windchill.

According to the results of this work may be noted that the use of

through parallel cycle from using different

specialized CAD although usually associated with marked

disadvantages, but, nevertheless, has shown its effectiveness and the

a significant reduction in the duration of pre-production of

Compared with the conventional sequential cycle.

2.1.2. Development of technological documentation matching algorithm

electronic

As mentioned in section 2.1.1, the need to ensure strict deadlines

on pre-production and production of a new spaceship

generation Modern satellites for various purposes requires

Use effective organizational and technical solutions,

including the automation of the CCI.

Effective direction of automation of technological preparation

production considered electronic agreement technological

documentation [27,28]. Automation in this area reduces the cycle

technological preparation of production and solve other problems.

To assess the development and approval costs

technical documentation has been designed classifier RKT details

allows to share the details of the milling and lathe-type in groups

Difficulty - Table 3
42

Table 3.

Classification of details according to the type and complexity of the group in agreement.

Type of parts to be processed on machine tools


difficulty

parts
Group

Woodturning milling

In the drawing, up to 30 dimensions. In the drawing, up to 50 dimensions.


Details are: Details are:
- 1-2 exact size (<IT9); - simple configuration, processing
- 1-2 simple milling element 2.5x coordinates;
- 1-2 simple milling element with the processing
(Hole machined flats groove) of the 3 + 2 (Lyska, groove, bevel, hole);

1 - 1-2 exact size (<IT9);


- processing for 1-2 INSTALL

In the drawing, up to 60 dimensions. In the figure, 100 sizes. Details are:


Details are:
- 6 to exact dimensions (<IT9); - configuration average complexity, processing
- more 2-milling 2.5-3h coordinates;
contours lying in one axis of symmetry. - 1-2 routing loop processing (3 + 2) x;

Details 1 group of complexity, requiring- may have up to 6 exact


additional size (<IT9);
matching at other - 1-2 INSTALL processing. details
2 structural subdivisions. 1 groups difficulties,
requiring additional
coordination in other divisions.
43

Type of parts to be processed on machine tools

difficulty

parts
Group
Woodturning milling

In the figure, 100 sizes. Details are: In the figure, 200 sizes. Details are:

- 10 to the exact dimensions (<IT9); - configuration average complexity, processing


2.5-3h coordinates;
- several milling - to 4 with the processing of routing circuits (3
contours lying in different axes of + 2) x;
symmetry. - 5x processing elements;
- 10 the exact size (<IT9);
3
- processing for 1-4 install.

On drawing more 100 In the figure, 200 sizes. Details are:


sizes.
details: - high complexity configuration, processing
- 10 have more accurate dimensions2.5-3h coordinates;
(<IT9); - 4 more routing circuits with processing
- have several routing paths lying in (3 + 2) x behind several
different axes of symmetry; install;
- complex surface from 5x
- require applications processing;
several special - 10 more precise dimensions (<IT9);
4 accessories; - processing for more than 4 install.
- treatment underway from
of a few (more 3)
Install.
44

Traditional under local automation process

harmonization of technical documentation on the part of groups 2-3 in complexity

paper form (Fig. 2.3) can be divided into 9 stages.

In the first phase developed technological documentation

transmitted leading engineer (or the head of the Bureau) for verification. Second

stage involves the compliance assessment documents a person certified for

this process.
stages Time, days processes

1 2

2 1-2 normative control

metrological
3 1-2
Technical inspection
workshop Checking

matching
4 2-3 control (BTK)

5 2-3 rationing
Coordination with
6 2-3

7 1-2 Head Office

approved
giving
Chief
8 1-2 Specialist

2 Technical department
September
14-21 shop Archive Archive TP

The information in paper form

Fig. 2.3. The process of review and approval process

documentation for details 2-3 complexity groups in paper form

On third stage technological documentation passes

metrological control authorized engineer, who

check the availability and accuracy of information, such as:

- parameters to be measured;

- measurement means;

- Conditions of measurement;

- the spelling of the metrological terms and notations.


45

These three stages are usually held in one unit.

In the fourth step documentation is being coordinated with

department of technical control for completeness control,

the adequacy of controls and compliance methods and means of control

product quality requirements of the CD.

Next is the standardization of process steps and operations

control in the division of labor norming.

The sixth stage involves coordination with the technologist tseha-

manufacturer for availability of equipment, technological and

control equipment embedded in the technical documentation.

Finally, on the seventh and eighth stages of documentation is

approval of the chief of bureau and chief specialist in the direction

(Head of Department).

At the last stage of technological documentation is assigned

inventory number and is the official copy for the department. Original

is transferred to the paper archive department of the developer.

Thus, the review and approval process

documentation developer sequentially transfers it to the paper form of

matching one person to another, simultaneously correcting arising

remarks. The time required for this process may reach 14-21 days.

The advantages of this process is the fact that the harmonization

conducted in accordance with established procedure and standard, this process does not require

powerful computer software and the corresponding knowledge of

persons involved. The main disadvantages are the processing time,

poor control over the execution and the lack of agreed and approved

technological documentation in electronic form, and such a requirement

presented to all newly developed products. Therefore, for

address these deficiencies was proposed reconciliation process


46

technological documentation in electronic form (Fig. 2.4) on the basis of

embedded in the corporation Windchill PDM-system.

A significant advantage of the automated systems of CCI

It is the performance of routine processes and the preparation of information

using electronic data processing means [29].


Stages
Time, days processes

1 2
metrological
inspection normative control
control
PDM Windchill control

2 1-2 Coordination with workshop

3 1-3 Technical control (BTK) rationing

4 1-2 Head Office

5 1-2 Chief Specialist

1-3 Technical department

June
7-14 Archive TP shop Archive

The information in paper form The information in electronic form

Fig.2.4. The process of review and approval process

documentation for details 2-3 groups of complexity in electronic form

In the first phase developed technological documentation

electronic form (CAD ADEM .adm file and the file for reading and comments

. pdf) is entered in the PDM Windchill DSE in a structure where there is already a

approved by the CD (with scanned signatures or electronically). After

This technologist starts the approval procedure and the message (letter) on

the need for harmonization are to be exercised

just three of the participant: checks normokontroler and metrology.

Working at the same time, they have the opportunity to make their corrections to the
47

. pdf-file and send the developer for revision or to agree

documentation.

After all the three participants in the documentation automatically

According to the algorithm is sent for approval to the workshop. Technologist

shop also receives a message about the need for reconciliation in

specified term and may agree on the documentation, or sent to

revision.

In the third step records again enters directly the 2nd participants

process. on regulation and technical control specialists work

parallel and can also send documents for revision or

to approve.

The fourth and fifth stages of the documentation is approved

sequentially according to the algorithm, after which a PDM system

"Of Windchill" it receives the status of "approved".

At the last stage of an agreed and approved documentation

members of the technical department is printed on paper, stamped

spetspechat and sent to the plant manufacturer [30,31,32].

In general terms, the negotiation process documentation

electronic form can be represented by the formula:

Tc TK
i
*. i (2.1)
i 1

Where T from - the negotiation;

TO i - return ratio on completion of documentation;

T i - the nominal time of negotiation,

T i
; T;
T ISM sc TKNT ; T; nb
T; T; G is . (2.2)

Where T ISM - time checking, compliance assessment and metrological

coordination;

T ai - time for approval to the workshop;

T TKN - time for the technical control and regulation;

T nb - time checking bureau chief;


48

T rc - the time for the approval of the chief specialist;

T the - time for work carried out Technical Department.

Thus, there remains six time stages, the passage of which at

implementation of the results is 7-14 days.

Thus the technology developer is in the workplace, and for

and approval process set clear control: in

any time can be seen at what stage is the documentation and who have

timing made coordination and approval.

From the diagram (Fig. 2.5), which shows the comparison of time indicators

The process of matching in electronic and paper form at an expense

minimum amount of time, it is seen that in the case of Harmonization

electronically produced time savings of up to 50%.

Fig. 2.5. Comparison chart of temporary indicators processes

matching in electronic and paper form as a result of the introduction of

Parts of the 2nd group of complexity


49

The results of the implementation process matching technological

documentation in electronic form are presented in Chapter 5.

Through the introduction of technological documentation approval process

electronically managed to solve the tasks at the same time

achieve some other positive results, namely [33]:

- reducing the time coordination of documents up to 50% due to

parallelism procedures when operating in a single information area,

where access to the technical documentation at certain stages

matching can implemented simultaneously several

matching individuals: process engineers from different departments,

Metrology engineer, engineer normokontrolerom and rationing,

Chief BTK;

- reception agreed and approved technology

documentation in electronic form;

- archiving system and ordering process

documentation;

- transparent control over the execution and approval in

specified period of time;

- release additional time in Developer

technical documentation during the approval of the workplace

in the common information area;

- the ability to view all the comments of matching persons on any

stage matching process.

2.2. The use of additive technology to reduce the complexity of

design STO

As mentioned in paragraph 2.1, the production of aerospace hardware is a single

in essence, in the general cycle of product development occupies a significant part of

technological preparation of production. Strict deadlines for the preparation of

production and manufacture of a new generation of spacecraft, as well as


50

modern satellites and other advanced products require CT

Use effective organizational and technical solutions with CCI

using high-tech methods of three-dimensional computer

modeling and creating hard copies of CT units and parts [34].

One of the areas of the CCI, requiring the use of effective

organizational and technical solutions from the use of modern

technology is the design of tooling.

The use of additive technologies can reduce the CCI and

the manufacture of such kinds of equipment as frame templates, copiers and others.

But the most telling example of increase of efficiency of CCI

the design SRT is an assembly of pipelines in a bundle (Fig. 2.7)

[35].

Fig. 2.7. "The beam" Pipeline

These nodes are used to transfer liquids and gases under pressure from one

spacecraft to other devices and are manufactured from

Aluminum or 'stainless' tubes with welded at the edges

wingtips. Composite pipes composed of individual pipes,


51

bent in space in a certain way and then assembled (soldered)

among themselves in a "bunch" into a predetermined position.

For products existing design by trial and hem

fittings on the product made of separate pipelines and standards

"Bundles" of pipelines, which is produced and a reconciliation of these newly

manufactured parts and assemblies.

Tube bending is made on universal devices, and control

geometry when verification is performed by applying to the standard. For

assembling and soldering beam USP are used to collect all of the standard "beam" of

standard elements. This technology is the production of these components strongly

It depends on the skill of the artist (Fitter) and does not provide high

positioning accuracy of the end of the "beam" of the pipeline, so at the last

stage when "beam" on the product requires manual Hem "in place."

Thus, the manufacture of parts and assemblies of this type for re

designed spacecraft, as well as taking into account the increased program

production output of the existing structure should be carried out at

the following tasks:

- reducing production cycle;

- reduction cycle of technological preparation of production;

- improving the accuracy of manufacture of individual pipelines and

"Beams";

- reduction of risks associated with the use of manual labor (loss

technologies as a result of the increasing trend of an aging workforce and

problems in recruiting and maintaining high-skill employees

working skills).

To solve these problems is proposed typical "beam" assembly technology

pipeline using information technology capabilities

(Fig. 2.8). In accordance with USP EMI developed, the active

process complexity and high labor intensity, the work requires specialist

qualifications. A particular difficulty is that for every


52

ending requires the development of a separate special member since they

positioned in space at different angles and you can not

applying standard elements for unambiguous reference position

endings. After that, the production of spetsdetaley for USP that

also it makes significant time costs. In the next step

assembles USP of special and universal elements.

Next, the assembly is controlled at the CMM.

Start

Inputs: KD EMP material

Development CD on universalnosborochnoe EMR


device according to (60 n / h)

Production nomenclature
spetsdetaley to USP (60 N / h) Manufacture of individual
pipelines
Assembling USP developed by KD
(16 N / h)

1.
Control (IMC) USP compliance
EMR (16 n / h)

Installation of separate pipelines


in USP assembly and brazing (18 n / h)

the end

Fig. 2.8. produce a "beam" Algorithm pipeline on the template

technologies
53

Separate lines after their production are set to

USP collected, recorded, and performed their assembly-welding "beam."

Thus, the production cycle "beam" pipelines made

about 170 N / h and technological preparation cycle - 60 N / h.

Testing of a sample carried out on modern technology

trubogibnom site, which includes a full range of equipment

(Including measurement of pipelines), allows you to:

- pipe manufactured by EMR predetermined shape with high precision;

- etalons scan the whole range of products of the old piping

construction;

- develop electronic models "beams" of pipelines, taking into account

scan data standards.

However, by using typical technology due to the large

the number of the nomenclature, "beams" pipeline decision of tasks

reduction of technological preparation of manufacturing terms and "bundles"

pipelines remains urgent.

the use has been proposed for solving these problems of additive

technologies, namely the method of selective laser sintering.

Technology of selective laser sintering (Selective Laser Sintering) -

technology of direct manufacturing parts from powdered materials by 3D-

According to the computer-aided design.

Laser Technology have formed a separate line technology

which combines both the traditional and some species

Industrial material handling (such as cutting, welding, drilling and

punching, marking and engraving, heat treatment, etc.),

and a number of fundamentally new technologies [36].

The latter include, the use of laser radiation for

create complex three-dimensional objects that are not available

in other ways in a single technological cycle. This problem is

the decision to use rapid prototyping techniques


54

combined with the technology of digitalization of physical objects and the subsequent

the direct implementation of the data on the technological laser

equipment. When using laser technology volume

shaping the resulting 3-dimensional object (item, model, etc.)

keeping the structure of the material in the volume, requires little or no

additional mechanical treatment [36].

An example of the most promising technologies is the SLS technology

DMLS - Direct Metal Laser Sintering, direct laser sintering

metal (EOSINT-270). As construction material used

powder materials. Powder is fed from a supply container and

using a special roller thinly spread over the surface

platform. The laser beam, sliding on the powder surface contour encircles

the first layer of a future model, and then scans the entire space inside

(Fig. 2.9.).

Fig. 2.9. Schematic diagram of the operation of selective laser setup

sintering
55

As a result, the thermal influence of the laser radiation particles

powder melted or completely melted (depending on

specific modification process and the material used), and after leaving

laser - hardened, forming a sintered or fused

structure. The process continues to generate the model layer by layer.

When this model is immersed in a bath of non-sintered powder which

It acts as a natural support. The working process takes place in a nitrogen environment and

provides the best among SLS technology purity surface [37].

Thus, the proposed assembly process "beam" pipe

based on electromagnetic radiation using the method as follows SLS

(Fig. 2.10, 2.11).


Start

Inputs: KD EMP material

Development of a prototype EMI beam (16 N / h).

Development of technological EMR


"Beam" prototype (8 N / h).
Manufacture of individual
pipelines
Making "beam" prototype
SLS method (60n / h).

Assembling USP prototype using


standard USP elements (8N / h).

Installation of separate pipelines in


USP and brazing the assembly (18 n / h)

the end

Fig. 2.10. produce a "beam" of the proposed algorithm piping

technologies
56

prototype fabrication by selective laser sintering

carried on today highly automated

production site for the manufacture of models, the working parts,

elements of the tool on the basis of specialized equipment

equipment company EOS (Germany).

In the next phase grown prototype installed at USP, and

USP is using the universal rotary members configured to

"Beam" Installation and assembly-brazing. After all the rotary

elements according to the position they are fixed and endings

"Grown" the prototype is removed from USP.

1 2

3
4

Fig. 2.11. The proposed assembly technology "beam" using the method

SLS: 1. EMR - Prototype 2 - 3. Setting USP - 4. Ready node


57

At the last stage the individual lines are installed on the USP in

according to a predetermined position, and after fixing them performed

assembly-brazing "beam."

As a result of such a technology, the following

results:

- technological preparation cycle - 24 n / h (reduced to 36 N / h, 60%);

- produce a "beam" pipeline cycle was about 110 N / h

(A decrease of 60 N / h, 65%).

In this way, implemented manufacturing process "beam"

pipelines using the SLS method allow:

- significantly reduce the complexity of the process of preparation

produce a "beam" pipelines;

- along with technological training reduce the complexity

producing piping bundle as a whole by the use of universal

instead of special rotary members;

- increase pipeline bundle manufacturing precision due to the work of

prototype EMI.

In this method of the patent of RF 2507432 [38].


58

CHAPTER 3. OPTIMIZATION OF PREPARATION

CASE perspective products RKT With EKR

3.1. Structural and technological features of the housing

prospective products with EKR

One of the promising products, which assumes the use of

the housing part with the wafer shell structure is a space

a new generation of vehicle.

housing a new generation of space craft (Fig. 3.1) is

is welded from several sectors of the truncated cone with EKR.

Fig. 3.1. General view of a new generation spacecraft

Waffle design a new generation of shell hull -

This thin-walled fabric made of high-strength aluminum

alloy with longitudinal, transverse or diagonal ribs,


59

formed at the intersection of cell and executed with the web as the

integrally [39].

Outer shell is a new generation of hull is

a plurality of segments of plates conical shape 30 mm

welded together, which are arranged in pockets size 100x100

mm and a depth of 28 mm. The wall thickness between the pockets with 4 0,2 mm,

the thickness of the bottom, respectively 2 0,2 mm (Fig. 3.2). surface roughness

given on Ra3.2mkm level.

Fig. 3.2. Estimated geometrical parameters of the body with EKR

a new generation of space ship

The radius of rounding of 10 mm at the corners, rounding radius of the bottom 2 is

mm.

Material mantle body - aluminum-scandium alloy 01570S,

also assumes the use of high-strength aluminum alloys,


60

such as aluminum-lithium alloy and V1469 for manufacturing AMg6

the housing parts of the power set (frames, brackets, fittings).

Comparative characteristics of strength properties [40-42] of these alloys

is presented in Table 4.

Table 4.

Mechanical properties of aluminum alloys

Mechanical properties of the alloys


Alloy
AT, MPa 0.2 MPa ,%

1 Aluminum-magnesium alloy AMg6 300 140 6

2 Aluminum-scandium alloy 01570S 373 245 15

3 Aluminum-lithium alloy B-1469 560 540 10

As seen from Table 4, the strength of aluminum promising

significantly higher strength alloys standard for aerospace

industry AMg6 alloy that must be taken into account in the assignment mode

and assignment processing tool life.

3.2. Study processability wafer shell structure

Manufacturability of product design - a set of properties

product design determining its suitability to achieve

optimal cost in production, maintenance and repair

for the given parameters of quality, output and terms of performance

[43].

Testing of product design manufacturability - part of the work on

providing processability, designed to achieve a predetermined level

technology and performed at all stages of product development. [43]

Workability the housing part with machined EKR

determined by the material for its manufacture in conjunction with its


61

geometrical dimensions, tolerances and surface roughness of surfaces

(3.1). In general, the workability can be represented:

TFMG IT Ra,. . . (3.1)

Where M - Details material;

G - geometric dimensions;

IT - dimensional tolerances;

ra - surface roughness.

With this in mind, EKR serves manufacturability estimate

technological coefficients (Fig. 3.3), representing

ratio of geometric parameters (3.2; 3.3):

Kp Hp Sp, / (3.2)

Where Kp - ribs coefficient;

Hp - the height of the ribs;

Sp - the thickness of the ribs;

KD ld sd, / (3.3)

Where KD - the bottom of the coefficient;

ld - the minimum length of the pocket;

sd - the thickness of the bottom;

Fig. 3.3. Geometric parameters of the EKR.

Taking into account the specified parameters of wafer structures,

used in the aerospace industry, namely: material -

high strength aluminum alloy, the tolerance on the thickness of the bottom and edges of 0,2 mm,

Ra3.2mkm roughness, processability analysis EKR housing part

based on the calculation of the coefficients Kp and KD.


62

The magnitude of the coefficients Kp and KD depending on manufacturability

ASD is presented in Table 5. These results were obtained on the basis of

Loading results and finite element analysis of wafer 12

shells forces acting during the cutting process.

In this way, research algorithm manufacturability at

the manufacture of products with a wafer shell structure looks

as follows (Figure 3.4.) after the end of construction products

It made working out on manufacturability, including including analysis

EKR workability by calculating coefficients Kp and KD.

Table 5.

The values of coefficients Kp and KD

Workability
manufacturability limitedly low-tech

(constructive technologically (Manufacturer with

size does not affect (Certain restrictions apply specified parameters

to receive it by mode It is high

parameters) processing) complexity)


Coefficient

kp <15 15 - 30 > 30

cd <40 40 - 60 > 60

By calculating the results of the decision:

- shroud with a waffle structure in the manufacture of technologically;

- shell with wafer design is technological, but for the production of

in order to minimize the complexity in debugging requires a

computational and analytical work to determine strategies and modes

processing;

- shroud with a waffle structure low-tech, there

great difficulty in machining to obtain the desired

design parameters as possible requires the design revision.


63

Fig. 3.4. Algorithm study workability in the manufacture of products with

wafer shell structure

Estimated wafer shell design Space Corps

a new generation of ship has a size 100h100h30mm pockets with thick

ribs 4mm and 2mm bottom.

rib ratio: Kp Hp Sp / 28/4 7th.

The coefficient of the bottom: KD ld sd / 100/2 50 .

Thus, carrying out calculation-processing required for the pocket

analytical work in order to avoid deformation of the bottom pocket of the cutting forces.

These works are a variety of strategies and optimization

Typical treatment regimes shell element with honeycombed structure.


64

3.3. Choice of machining strategies typical element wafer

design

Model element wafer pocket structure is.

For the analysis of an exemplary take estimated shroud

waffle design a new generation of spacecraft with predetermined

parameters (Fig. 3.2).

Based on the geometry and material of the workpiece being processed, select

cutting tool for finishing aluminum alloys - end

cutter diameter of 16 mm and a radius of 2 mm at the end.

Plunging strategy and machining of pockets are well known, their choice

It may depend on several factors such as the geometric parameters

processing elements, the geometry of the cutting tool, the possibility of

equipment specified tolerances and surface roughness. Consider

optimization strategies and options for insertion through processing

CAD ADEM capabilities [44-45].

Since the interior of the pocket is a closed loop, the

beginning processing passage with a depth from the approach to implement

impossible. Therefore, before processing passes to cavity depth

infeed is due to this depth, or pre

perform an opening for the entry of the cutter.

Variant with holes pretreatment less preferred,

because adjustment is required, the installation and use of additional

tool time tool change, while the complexity of such

treatment comparable to plunge modern carbide cutters

for aluminum. Furthermore, on the last pass infeed process

cutter anyway required, as cone on the end of the drill will not allow

perform the hole without touching the bottom of the pocket plane.

Therefore, further consider the options on the cutter infeed strategies

passage depth. We can distinguish three fundamentally different strategies


65

incision, most commonly used in the processing of cavities

closed loop:

- plunging "vertically" (Figure 3.5.) - motion cutter vertically downward,

similar to the movement of the drill. Characterized by small supply and

the occurrence of high loads at the end of the infeed and move to

processing a predetermined depth on the cutting feed passage, which may lead to

deformation of the pocket bottom. Only suitable for milling, having a tooth on the end of a

"Overlap".

- plunge "spiral" (Figure 3.6.) - the movement of the cutter down to 3

coordinates at the same time along a helical path. characterized

high feed comparable with the main feed processing load

the time of transition to processing for applying a predetermined working depth of the passage

minimal. After insertion is well specified diameter infeed,

which is then treated with cutter traverses passageway depth. In the moment

the entrance to the pit and out of it at the work feed mill tests

multidirectional load surges, which negatively affects its

resistance, limits processing modes and roughness worsens

the bottom surface of the pocket. Suitable for most modern mills,

having the opportunity to plunge angle.

Ds

Dr

Fig. 3.5. Insertion "vertically"


66

- plunge "twist on a path" (Figure 3.7.) - the movement of the cutter on the 3rd

coordinates alternately changing direction equidistant contour

processing.

Ds
Dr

Fig. 3.6. Insertion "spiral"

Dr ds

Fig. 3.7. Insertion "spiral along the contour"


67

Characterized by a high pitch, comparable with the main feed

processing load at the time of transition to a predetermined depth processing passage

minimal. After infeed remains well having a geometry,

equidistant processing circuit which then intersects with cutter

processing pocket layer testing smooth load changes, since and

well, and the trajectory of the cutter motion for "equidistant" policies and

"Spiral" are equidistant paths. This strategy is suitable for

Most modern milling cutters, having the opportunity to plunge angle.

From the standpoint of computer time insertion process described above

policies are not fundamentally different. Insertion "vertical" has

smallest path length, however, and the minute feed is much lower

than that of the next two strategies. Strategy "spiral" and plunge

"Spiral contour" have approximately the same length

trajectories and supply quantity, so machining time identical

(Table 6).

In this way, based on the analysis, We accept

optimal strategy spiral incision along the contour - it provides

movement of the cutter with smooth load variations, allowing you to work on

high cutting conditions and is suitable for most modern

cutters.

Next, consider the possible pocket machining strategies on the basis of

CAD CAM capabilities ADEM module.

In principle, you can select 4 types of strategies that can be

used for the treatment of the pocket, it is:

- "Zigzag" - rectilinear motion cutter along one side

contour shifted by the amount of cutting depth for cutting feed along

the other side of the loop (Fig. 3.8). This strategy is characterized by frequent

changing direction 180 and the change counter to a passing circuit

milling and vice versa, which adversely affects the durability

instrument, as the processing and requires correction processing modes


68

in the direction of reduction. With such a strategy, as a rule, it takes the last

finishing pass for the remaining scallops on both sides of shifts at

the magnitude of the cutting depth.

Table 6.

plunging strategy

Strategy "Spiral
"Vertical" "Spiral"
Criterion the contour "

Feed, mm / min 80 600 1200

Rotation frequency,
1200 6000 6000
rev / min

Cutting speed,
60 300 300
m / min

Stress on high, high, Min,

(tool P, M cr.) variable variable constant

With an opportunity With an opportunity With an opportunity

Tool vertical insertion insertion

insertion angle angle

T mung bean, s * 0.39 0.42 0.43

* - processing data in one layer with a predetermined size pocket plunging

cutter diameter of 16 mm and a radius of 2 mm at the end.

- "Loop" - the linear movement of the cutter along one side

loop in one direction, with the shift by the amount of cutting depth after

rise in the plane of idle strokes. This strategy is characterized by

choice counter or concurrent milling and circuit

the need to lift the tool plane and idle strokes

for each subsequent insertion by the amount of shear cutting depth (Fig.

3.8). When "loop" strategy requires final finishing pass because

remaining ridges on the sides of shifts by the amount of cutting depth.


69

All these factors greatly increase the complexity of processing

pocket.

Fig. 3.8. Strategies for handling "zigzag" and "loop"

- "Equidistant" - finishes the pocket along the contours, equidistant

the contour of the pocket, with a shift in the depth of cut from circuit to circuit (Fig.

3.9). This strategy is characterized by uniform load on the tool when

movement along the contours and load changes during the transition from circuit to

circuit that requires correction processing modes in the direction of reduction.

Fig. 3.9. "Equidistant" treatment strategy without function and function

rounding path
70

When using the "equidistant" strategy significantly reduced

load jumps and application functions fillet radius at the corners of administration

trajectory allows to intensify treatment regimens (Fig. 3.9). at

such a strategy in most cases does not require finishing pass on

the contour of the pocket, it is the last equidistant passage.

- "Spiral" - finishes the pocket along the path in a spiral with a pitch,

equal to the depth of cut (Fig. 3.10). This strategy is characterized by a constant

the load on the tool during the entire pocket machining time that

It maximizes intensify treatment regimens. application

administration functions the rounding radius in the corners also allows the trajectory

intensify processing modes (Fig. 3.10).

In most cases, it does not require finishing pass along the contour

pocket, equidistant last passage is formed automatically.

Fig. 3.10. treatment strategy of "spiral" without function and function

rounding path

Thus, the optimal treatment strategies should pocket

take the "spiral" with the function of the introduction of the radius of curvature as a strategy,

providing maximum performance and smooth operation.

Comparative characteristics of strategies are presented in Table 7.


71

Table 7.

Strategies processing pocket layer

Strategy

"Zigzag" "A loop" "Equidistant" "Spiral"

Criterion

Stress on high, high, low Min,

tool short short short constant

Plunge Single Multiple Single Single

clean
required required Not required Not required
passage

limited as
limited limited Not
Mode transition from
excesses multiple limited
processing circuit to
path plunge maximal
contour

T * mach., min 7.4 8.4 6.36 6.04

* - data at a constant insertion scheme "spiral of contour"

Thus, the presented recommended pocket Processing Technology

(Figure 3.11.):

Fig. 3.11. Recommended pocket Processing Technology


72

- processing one pocket tool - endmill diameter

16 mm and a radius of 2 mm at the end;

- Insertion strategy: "twist on a path";

- treatment strategy pocket layer "spiral" with the introduction of the function

rounding radius;

- cutting width (dimension along the axis of the cutter) 5.4 mm, cutting depth 8 mm

[46] walls completely at the bottom with an oversize pre 1mm finishing

processing.

3.4. Optimization of treatment regimes in order to avoid deformation

waffle design elements with preset parameters

As was shown in section 3.2, as a result of mining on

manufacturability alleged EKR spacecraft body new

generation to eliminate the need to optimize the deformation mode

processing the bottom pocket.

Therefore, the cutting mode selection criteria will be the minimum force

cutting acting on the bottom of the pocket at the moment when the finishing recessing

processing, and maximum productivity.

To select a processing mode mantle waffle structure

Space a new generation hull should:

- calculate the forces and the contact loads when milling

end mills aluminum alloy with given characteristics;

- based on the calculation algorithm to develop a program for calculating the forces

cutting elements acting on the sleeve with a waffle structure;

- with the help of the developed program to obtain the values of cutting forces and

pressures in various ranges of processing conditions;

- develop a pocket load of waffle shell model

structure at the time of maximum deformation;

- using the finite element method to make loading forces

cutting respective surfaces and evaluate emerging strain;


73

- based on the results of the loading modes to identify areas

processing which provide the pocket with predetermined

parameters.

3.4.1. Calculation of forces and the contact loads when milling end

cutters aluminum alloy with desired characteristics

To optimize the cutting conditions with the deletion strain

EKR cells calculated forces acting pocket milling. AT

the basis of calculation used a technique developed at the Department of MT-2 Bauman

them. NE Baumann, but the feature of performing the calculations in

work is to determine the forces and pressures from the end milling edges.

Fig. 3.12 shows the position of the cutter at an angle for insertion

fine milling the pocket bottom. On the part of the radiused edges 23 and

end edges 34, 56 on the bottom of the pocket forces act: 223234256 PPP. . .

Fig. 3.12. Insertion scheme applied forces and pressures for finishing

processing pocket bottom


74

The end mill has design parameters: External diameter d,

number of teeth z, radius at the apex of the tooth r, corner angle,

.
auxiliary angle in plan, 1. respectively. Cutter handles groove

or c ledge cutting width B ( dimension parallel to cutter axis) and depth

cutting t ( dimension perpendicular axis). linkage parameter

process are: tool rotation frequency n, innings s, which in general

the case has a direction at an angle to the longitudinal movement of the table

milling machine. The general scheme of the kinematic parameters and sections

cutting layer is shown in Fig. 3.13.

Here, the cutting edge of the tooth is divided into three portions: a helical edge 12

angle of inclination to the cutter axis 0 on the cylindrical part, the edge 23 radiusnaja

with radius r, the end edge 34 at the auxiliary angle in terms of 1.

The width of the helical tooth edge on the cylindrical portion of the cutter b ( 3.4)

It is defined as the length of a helix with helix angle 0:

2 2
d H tg 0
b ( B rd )
2 2
. (3.4)

where H - the step helix.

Radius edge is divided into elementary sections, each of which

It has a width i where


brk, / k - the number of plots, the radius relative to the axis i R and

angular coordinate i.

The front edge has a width (3.5)

d /2 rb
j
cos 1 . (3.5)

R.j
edge center lies on a radius

The greatest thickness of the slice to the screw tip, if the depth of cut

less than half the diameter (3.6) is

as sin cos
z 0 . (3.6)

s - feed per tooth, mm / tooth;


Where z
75

0- contact angle.

For other depths

as cos
z . (3.7)

To calculate the slice thickness at the elementary radiused portion

consider the general case of a direction at an angle in the diagram Fig. 3.13.

here, the vector c ( 3.8), which coincides with the direction of flow in the system

coordinates XYZ, tied to the elementary section so that XY - basic

plane, Z - direction tangential to a circle of radius R i, is equal to:

cs z sin i cos sin j cos cos 0 k.


0
(3.8)

The thickness of the shear layer (3.9) is measured in the base plane

PP
o
XY oand
( is) as follows:

ai c xy cos i
sz sin cos i
cos sin 0 sin i
. (3.9)

c n - normal to
Where xy - vector projection c to the main plane vector i

the cutting edge at the point i, i- the angle between these vectors.

For the end edge of the slice thickness of (3.10):

a s z sin ( 1)
j
. (3.10)

Power parameters are calculated for the total milling circuit

endmill groove (shoulder) with feed at an angle to the longitudinal movement

Movement table of the milling machine. Considered the Power output

Separate the edges: screw 12, radius 23, the end 34 (Figure 3.14.).

Shows the corresponding section of the blade: NN, N 1- N 1, N 2- N 2. each

sectional edge has a rounding radius . a point A divides the slice thickness

a on chips and deformed skin layer thickness h. point A

corresponds to a negative rake angle k. On a front surface with

R angle of action
shaving instrument side to a force c to

cutting speed v. On the rear surface side cutter to the treated

P and tangential force 2 F.


surface acts normal force 2
76

Fig. 3.13. The scheme for calculating kinematic parameters and cutting layer

To calculate the mean shift angle (3.11) is used

expression takes into account the influence of the parameters of the shear layer and the elastic

properties of the processed materials and instrumentation on the proposal

Starkov VK [47] and after transformation becomes:

1.08 ( 4
E1ba/) Cos sin
/ 2 arctg
cos sin
. (3.11)
77

wherein the elastic constant of two contiguous bodies (3.12) is


2
E,2
2
(1 )/ E1 (1 )/
1 2
(3.12)

Where E 1, E 2 - elasticity module processes and tool

materials;

12 - Poisson's ratio;

a, b - width and thickness of the shear layer;

- medium rake angle as rounded edges.

velocity factor K L ( chip shrinkage) is defined through angle

shear by the known formula [48]

K L cos ctg sin


. (3.13)

and the angle of action between the resultant force on the front

surface and the cutting speed is calculated with a correction '

proposed in [49-50]:

tg ( )
/4 ' . '
tg ( ) 2. (3.14)

Expressions (3.11) (3.14) experimentally checked and

used to calculate the phase angle for turning by one of the authors

[51].

The resulting force chip (3.15) is directed at an angle

actions and a cutting speed determined through the tangent force

shear plane P

P p ab
Rc . (3.15)
sin () cos ( ) Sin () cos ( )

Where p - tangential stress in the shear plane.

Then the expression for the calculation of the tangent and normal components

forces on the front surface of the instrument (3.16, 3.17) can be determined

of geometric relations:

FR c sin ( )
1
. (3.16)

PR c cos ( )
n . (3.17)
78

Fig. 3.14. The scheme of calculating the forces and contact stresses
79

and costavlyaet power chip along the axes ZY. ( 3.18, 3.19)

will be equal to, respectively:

RR
cz c cos . (3.18)

RR
cy c sin . (3.19)

Taking the hypothesis that the maximum value of the contact pressure along the entire

cutting edge of the same, this value can be expressed by the normal force on the front surface and

the contact area (3.20)


Pnm
n( 1 1)
. (3.20)
lb
1

Wheren1 - exponent diagrams for the contact pressure (3.21)


n1
p
(1
m m, ) (3.21)

Where m - relative distance from the cutting edge along the front surface of the tool.

The exponent is assumed to be n 1 = 1, i.e. contact normal

on a front surface pressure is distributed in a triangular orthographic drawing.

The contact pressure has a maximum value at an arc length AB, which is determined by

the depth of the layer crushes (3.22):


h /3
. (3.22)

On the length of the arc resulting force acts (3.23):

P mm AB b.
(3.23)

which is directed at an angle to the axis Y. This force is decomposed into

components along the axes, ZY ( 3.24, 3.25):

PP
mz m sin . (3.24)

PP
my m cos . (3.25)

To the rear surface it is assumed that the normal contact pressure is uniformly distributed.

Then the normal force P2( 3.26) to

wear area z h determined via a contact pressure and contact area,

and tangential force 2 F ( 3.27) is calculated through the average coefficient of friction:

P2 mzhb, (3.26)

FP
2
f 2 tr . (3.27)
80

Defining tangential forces acting in the direction of the velocity

Cutting along the axis Z, you can calculate the total torque cutting

(3.28)

MMMM,12 3 34 (3.28)

where the terms correspond to the cutting edges:

- screw

dz p
M 12
( RPF
cz mz 2 ) Year . (3.29)
2000

- radius (summation of elementary areas)


k
R izpi
M 23
( R czi P mzi F 2 i ) 1000 . (3.30)
i 1

- front

R jz pj
M 34
( R czj P mzj F 2 j ) 1000 . (3.31)

Where z p - the number of simultaneously cutting teeth for the respective

edges that make up the cutting forces are determined by (3.18) (3.19) (3.24) (3.25)

(3.26) (3.27).

Cutting power is calculated by the formula [52]:

N Mn / 9554 . (3.32)

In accordance with the scheme of Fig. 3.13 tool has tooth blade

a force on the treated surface of the wear area

value z h and the arc of the cutting edge AB. Here it is assumed uniform

contact pressure m. The magnitude of this pressure is one of

output parameter calculation algorithm and used for

modeling the deformation of thin-walled parts made of aluminum alloys.

3.4.2. Development Program (Trailer_mill) and the calculation of the cutting forces,

operating elements on the sleeve with a waffle structure

In accordance with calculation method described in 3.4.1, is designed

a program for calculating cutting forces acting on the shell elements in


81

milling (A.1). To this end the source data defined for the selected

Aluminum alloy (01570S) and grade cemented carbide (VK6M) - (Figure 3.15.):

d - diameter of the end mill;

z - number of teeth of the cutter;

t - cutting depth;

B - width of the milling;

S z - feed per tooth;

n - rotational speed of the spindle;

r - the radius of the top cutter tooth;

h z - wear amount on a back surface;

- penetration angle and others.

Calculation results for the helical edge 12 radiused edge 23,

end edge 34, 56 are (Figure 3.15.): Maximum values

contact pressure, torque, power, normal force P 2 and

other parameters. The calculated parameter values are displayed on the form

programs and the resulting result.txt file.

Fig. 3.15. Trailer_mill calculation program interface: the left - the raw data;

Right - results
82

As was shown in Section 3.2, for the assumed structure EKR

Space a new generation hull necessary to carry out

calculation and analytical works in order to avoid deformation of the bottom pocket of strength

cutting, in particular, optimizing the cutting conditions for finishing

pocket bottom.

Using Trailer_mill program will calculate the force acting on the bottom

pocket for insertion in different cutting conditions. Of all the parameters

cutting conditions on the force acting on the bottom of the pocket, will affect the angle

Insertion , feed per tooth S z, depth t and width AT milling. Frequency

Spindle rotation is influenced to a small extent, since

treat a range of cutting speeds do not fall into the zone

high-speed processing and a sharp decrease in cutting forces

due to local thermal softening of the metal, i.e. the process

handling is subject to the ordinary laws of cutting. inability to use

HSC due to the use of bulky,

having high inertia equipment, and lack

TC rigidity due to the need to use the milling cutter with

Long reach in conjunction with the processing of the base member "suspended"

when, in particular, the bottom of the pocket and, in general, all the external cone

surface, has no direct bearing.

Bearing spindle speed n = 6000ob / min, the parameters

shear layer at the final instant infeed B = 1 mm, t = 16 mm, the tool -

solid carbide cutter 16 R2 MasterCutTool R2,0 z = 2 (Fig. 3.16)

maximum allowable wear amount on the rear surface h zmax = 0,1mm

[53], we calculate the force acting on the bottom of the pocket at the final instant

infeed. This force is composed of several forces arising from the 3

edges: Radius 23 and 2 end 34 and 56 (Figure 3.12.) at these edges

forces will change in different ways.

The calculation is performed for supplying the values S z = 0.05; 0.083; 0.1; 0.15; 0.2

mm / tooth, while the range of = 3 ... ..31 with division by 2 . Results,


83

obtained in the calculation (see. Table 8 ... 13), used for loading

CAD design CATIA and evaluation deformations arising and

stress.

Fig. 3.16. Solid carbide end milling cutter MasterCutTool R2,0 z = 2

3.4.3. Qualification stresses and deformations arising during finishing

processing the bottom of his pocket, and recommendations for treatment regimes

To evaluate the stresses and deformations arising during finishing

processing the bottom pocket, use module "Analysis and Modeling"

CAD CATIA. The calculation of deformation bottom (Fig. 3.19) and

equivalent stress eq ( Mises) (Fig. 3.20) for processing modes

in accordance with Table 8 ... 13.


84

Table 8. Table 9.

Force at S z = 0.05mm / tooth Force at S z = 0,067mm / tooth

Table 10. Table 11.

Force at S z = 0,083mm / tooth Force at S z = 0.1mm / tooth

Electronic model contains 9 pretreated pockets,

loading exposed central pocket, all hand model


85

enshrined in the anchorage, the bottom of the entire model is in free

state (Fig. 3.17).

Table 12. Table 13.

Force at S z = 0.15 mm / tooth Force at S z = 0.2 mm / tooth

Fig. 3.17. load model


86

Coordinates force application pad obtained in the simulation

CAD processing ADEM and have a distance from each of the pocket walls

(44 mm, 44 mm). The calculation is made in the end position of the tool during

insertion, when the cutter reached the finishing surface of the floor, for this

in the model of the cutter a recess depth of 1 mm (the value of allowance).

the loading area is a contact pad and cutter

parts during cutting, which is 0.1 mm in view of wear and the received initial

rounding the cutting edge radius of 0.01 mm has dimensions of 0.108 mm x 14.7 mm

yield over the edge radius (Fig. 3.18).

This model is comparable to the load on the characteristics of the model

segment, while simplifying and speeding up the calculation on PC in

CAD CATIA.

5 6

4
March

Fig. 3.18. Scheme loading pocket bottom


87

In this loading floor model performed via pad 23, 34 and 56

in accordance with the results of the calculation of the forces and the diagram in Fig. 3.12. Through

CAD CATIA conducted by finite element calculation of deformation

bottom (Fig. 3.21), and equivalent stress (Fig. 3.22). The values obtained

bottom deformation and equivalent stress eq ( Mises) are included in the

Table 8 ... 13.

According to the results of calculation of forces and loading models with waffle

construction (Fig. 3.18) constructed according bottom deformation and

equivalent stress eq from the infeed angle for different values of

feed per tooth S z: () and eq ( ) (Fig. 3.19 and 3.20).

In the graph of eq ( ) (Fig. 3.20) can be isolated area 2

values 4 and 5. In the 4 voltages do not exceed the value of

alloy yield strength of 01570 ( m (01570) = 245MPa), which indicates the elastic

the nature of the strain when working with such cutting conditions. In region 5

voltages higher than the yield stress value of 01570 alloy,

this leads to plastic deformations bottom pocket, which is unacceptable.

, mm

1 ,

Fig. 3.19. Graph () at various S z


88

eq, Mpa

t = 245

Fig. 3.20. Graph eq ( ) with various S z

Fig. 3.21 Calculation of deformations in CAD CATIA


89

In the graph according () (Fig. 3.19) 3 area allocated values

1, 2 and 3. In the range of 1, the value of deformation in the pocket bottom end

Insertion time is not more than 0.03 mm. Such deformation amount not

essential, during the transition movement of the cutter in the horizontal bottom feed

pocket will original state, the tolerance on the thickness of the bottom and

surface roughness ( 0.2 and Ra3.2) does not exceed the permissible

parameters.

The range of values of magnitude 2 strains pocket bottom in the final

Currently infeed reaches 0.18 mm, which is also not lead to failure of tolerance

the thickness of the bottom. Note the resulting voltage

these values (Fig. 3.20) to prevent plastic deformation

EKR cells.

Fig. 3.22 Calculation of stress in CAD CATIA


90

In the range of 3 deformation magnitude in the pocket bottom end

Currently infeed reaches 0.28 mm. In addition, the value of the third field

fall into the zone of plastic deformation the bottom (Fig. 3.20), so the result

processing such modes will exit from the bottom thickness and tolerance

residual deformation.

Gradation charts explains the results of the calculation of forces on

edges in Trailer_mill program. This is due to the fact that the value of

vertical feed component for insertion is small and increases with

increase in the total feed per tooth S z and insertion angle . Therefore, when

low values of the feed per tooth S z and insertion angle value

the vertical component of feed to end teeth may be less than 0.01

mm, i.e. less than the radius of the rounding of the teeth edges. In fact, in this case,

end edges 34 and 56 are not involved in the cutting, and the entire allowance is removed only

Radius edge 23, and therefore the program calculates the zero Trailer_mill

value for the end edges. As the feed per tooth S z and / or the angle

Insertion value of the vertical component feeding teeth on the end

increases, and the work is turned one first end edge, and then

second. This is clearly seen in Fig. 3.19, where Zone 1 is only Radius

edge 23, in the area 2 - 23 and the end edges 56, and in zone 3 and are involved in the cutting

Radius edge 23 and both end edges 34 and 56. It should be noted

that the second (opposite) edge radiusnaja at a predetermined point in the

is not involved, since allowance has been removed edges 23, 34 and 56,

and loading her work is not taken into account.

Thus, the optimal one for finishing the bottom

pocket defined parameters (Fig. 3.2) and in specified conditions will range

processing modes that fall within the zone 1 and the zone 2

voltage limits (Fig. 3.19, 3.20). Processing on such modes

It allows to stably obtain a pocket with the specified parameters within

wear on the cutter rear surface is not more than 0.1 mm.
91

3.5. Methods of optimization shell with wafer processing technology

design

According to the results of calculation of forces and stresses the optimization of

cutting mode parameters that directly affect the deformation of the bottom, and

is the feed per tooth S z and insertion angle ( Fig. 3.23). The calculation was performed for

different ranges bottom ratio KD.

40 <Kd <60 60 <Kd <100


S z, mm / tooth

0.25

0.2
S m = 2000 mm / min

0.15

S z = 1,92- 1.36
0.1

S z = 0,62- 1.32
0.05

0 5 10 15 ,20

Fig. 3.23. Schedule Optimization treatment mode parameters when EKR

different values KD

FIELD acceptable parameters when processing cutting conditions bottom EKR

from KD less than 40 is not limited due to the absence of significant deformations

bottom.

FIELD acceptable parameters when processing for bottom EKR KD more

40 and 60 is less limited by the equation (3-33):


1.36
Sz 1.92 . (3.33)
92

Then, at an angle of insertion = 7 maximum flow is S z = 0.15

mm / tooth at an angle of plunging = 9 maximum flow - S z = 0.1 mm / tooth.

FIELD acceptable parameters when processing for bottom EKR KD more

60 and less than 100 is limited by the equation (3-34):

1.32
Sz 0.62 . (3.34)

Processing shell with a waffle design can be carried out

only minimal processing modes = 5, S z = 0.05 mm / tooth.

Limiting the maximum flow S z = * 0.17 mm / tooth (Fig. 3.23) is due

minute maximum feed S m = 2000 mm / min in connection with the inertia of

machining of large parts on CNC machines.

Based on the results, the technique of optimization

processing technology with the wafer shell structure provided in

an algorithm (fig. 3.24) [71].

Thus, the manufacturability of the proposed wafer analysis

design, selection of treatment strategies, optimization of treatment regimes,

which includes the calculation of forces when cutting in Trailer_mill program in conjunction with the

loading CAD and calculation of stresses and strains Finite

elements, allow to optimize the technology of shell

with a waffle structure, and this technology makes it possible to obtain

set design parameters and maximum performance

combined with the stability of the processing results.


93

A shroud housing a waffle


structure

Testing for manufacturability wafer shell structure


calculation process with
coefficients

Selecting the types of elements of strategies for treatment

waffle design

Optimizing processing conditions in order to obtain predetermined


parameters mantle waffle structure

Calculation of efforts The calculation of strain and


Trailer_mill program during stress, assignment
mechanical working processing modes

Technology for producing a wafer shell structure

with preset parameters

Fig. 3.24. Method of optimization processing technology with the housing part

IN TO
94

CHAPTER 4. EXPERIMENTAL STUDIES

Machinability of high-strength aluminum

ALLOYS.

4.1. Research objectives and indicators of machinability

Application in promising products RKT new aluminum-lithium

(B-1469) and aluminum-scandium (01570S) alloys, much

superior in mechanical characteristics previously applied

Aluminum-magnesium alloy (AMg6) requires the determination of machinability and

develop effective technology milling these alloys.

Research goals - reducing the complexity and manufacturing costs

parts of high-strength aluminum alloys at the present

CNC equipment by optimizing cutting conditions during machining

processing.

Machinability of materials - one of the most important technological

properties that characterize a set of quality material, which determines the

the ability of the material be treated with cutting tools.

In conducting research as an indicator of workability

We will use:

- surface quality (roughness);

- processing performance (4.1) [54]


Q s Bt / 1000 s zznBt / 1000,
m cm 3 / min, (4.1)

Wheresm - minute presentation,

s z- feed per tooth,

n - a spindle rotation frequency,

B - milling width,

t - milling depth,

z - the number of cutter teeth.


95

- cutting force, power, torque;

- wear and tool life.

Investigation of the influence of cutting conditions on the workability

aluminum alloys carried out under production conditions CJSC "MEM"

RSC "Energy" and in the laboratory of the department "Technology and Instrumental

technology "MSTU. Bauman [55-58].

4.2. Study of the dependence of the roughness of cutting mode

4.2.1. Equipment and tools for conducting experiments

roughness parameters were measured on the treated surface

workpieces and samples treated at a cutting modes according to

up experiments. For measurement of roughness parameters

used portable profilometer Surftest SJ-301" (Fig. 4.1).

Fig. 4.1. The process of measuring the surface roughness on the end of the groove on
portable profilometer Mitutoyo Surftest SJ-301
96

On workpieces milled grooves, each of which is processed in

specific cutting conditions. For each slot provided for the measurement of

roughness parameter Ra (according to the 3rd measurement) on the end face and

the side walls. The measurement results shall be recorded.

Research carried out in the production shops of JSC "MEM" for 5

OC vertical coordinate TOYODA UG550 (Fig. 5.3) and 4-x

coordinate OC TOYODA FH550SX (Fig. 4.2).

Fig. 4.2. Machining center TOYODA FH550SX

For research use modern cutting

Instruments of various companies equipped with tool materials,

intended for the treatment of aluminum alloys:

1) The end mill 32 mm diameter Iscar HM90 EAL-D32-C32-L150-

Z = 3 15 [59]; plate Iscar HM90 AXCR 150504R-P IC28 (Figure 4.3.);

2) The end mill 25 mm diameter Iscar HM90 EAL-D25-C25-L140-

15 z = 2; plate Iscar HM90 AXCR 150520R-P IC28 [60];

3) The end mill 16 mm diameter Guhring 16.0 z = 3202 4 (Figure 4.4.) [61];

4) The end mill 16 mm diameter Master Cut Tool R2,0 z = 2 [62];


97

5) The end mill 16 mm diameter Walter H602091-16-24-2 z = 3 [63];

These cutting tools are available on the Company "MEM" and

used in processes for the machining of

aluminum alloys.

Fig. 4.3. workpiece handling of aluminum-lithium alloy modular

endmill Iscar HM90 EAL-D32-C32-L150-15

4.2.2. The practical results of the processing end mills

For the 3 types of cutters are well-established in the JSC "MEM"

when processing aluminum alloys performed univariate experiment

where the fixed one of the parameters of cutting conditions (speed in turns

spindle or minute presentation).

1) - end-piece carbide cutter with a diameter of 16 mm z = 4, Guhring,

- Machine TOYODA UG550

- groove processing 16x8 mm.


98

Fig. 4.4. A billet of aluminum-lithium alloy on the table milling


machine. Processing mill Guhring 3202 16.0

As follows from the graphs (Fig. 4.5), the roughness of the end

surface of the groove is in the range of less Ra3,5mkm and significantly less

than the roughness of the side surface of the groove. The roughness of the side

surface with increasing flow of up to 2800 mm / minute (0.085 mm / tooth) reaches

Ra12mkm values. For all graphs characteristic dependent increase

roughness with increasing feed milling.

The effect on the roughness of the spindle at constant speed

feed per tooth s z = 0.08 mm / tooth is reflected in the graphs (Fig. 4.6).

When changing the spindle speed in the range from 4800 to 10400

rev / min roughness of the end surface of the groove is within Ra1,5-

3,8mkm, the side surface of the groove within Ra3-17mkm. Absent

a unique relationship between the value of spindle speed and

the roughness of treated surface.


99

Fig. 4.5. Plots of the roughness Ra of the side walls and end

groove on s z when n = 8120 rev / min

Fig. 4.6. Plots of the roughness Ra of the side walls and end

n from the groove when s z = 0.08 mm / tooth


100

2) - the end mill 16 z = 2 R2 Master Cut Tool 88140R2,0

- Machine TOYODA UG550

- groove processing 16x8 mm.

We studied the effect of feed, spindle speed

roughness on the machined surfaces in the processing recess 16x8 cutter

solid carbide diameter of 16 mm Master Cut Tool R2,0 z = 2. graphics,

characterizing Depending on the effect of the studied factors on

machined surface roughness are shown in Fig. 4.7, 4.8.

Fig. 4.7. Plots of the roughness Ra of the side walls and end

n from the groove when s z = 0.08 mm / tooth

When processing for groove milling Master Cut Tool z = 2 R2 roughness

the treated surface is within Ra0,15-0,8mkm (grade 7-8

roughness) in the investigated range of speeds and feeds

spindle. Such a high surface quality is due to stable

operating conditions, lack of vibrations, small torque the cutting point

for cutters with number of teeth z = 2.


101

Fig. 4.8. Plots of the roughness Ra of the side walls and end

groove on s z when n = 8000 rev / min

3) - end mill 25 mm diameter team Iscar HM90 EAL-D25-

C25-L140-15, plate Iscar HM90 AXCR 150520R-P IC28

- Machine TOYODA UG550

For team terminal cutters (Fig. 4.9 4.10)

roughness of the machined surfaces at the groove processing is

less Ra5mkm (class 5), in the processing of the step - less Ra2mkm (class 6).

The values of roughness of the processed surfaces can be improved

the transition to a more powerful and hard OTs TOYODA FH550SX.

4) - an end mill 32 mm diameter team Iscar HM90 EAL-D32-C32-

L150-15; plate Iscar HM90 AXCR 150504R-P IC28,

- OC TOYODA FH550SX

- groove processing

The results of a series of experiments for the team end mill (Fig. 4.11,

4.12) show that the roughness of treated surface is

less Ra0.6mkm (8 class).


102

Fig. 4.9. Plots of the roughness Ra of the side walls and end slot
from s z when n = 5100 rev / min

Such high quality of treatment can be achieved stable

anti-vibration operating conditions, when the allowable torque at

spindle machine far exceeds the time of cutting.

Fig. 4.10. Plots of the roughness Ra of the side walls and


end of the groove when n s z = 0.225 mm / tooth
103

Thus, depending on the roughness obtained by frequency

minute spindle rotation and feed for each cutter during processing

aluminum-scandium alloy 01570S. In general, with increasing feed

roughness increases, but remains Ra1,6mkm within that

It meets the requirements of the product CD.

4.2.3. Depending on performance, power, torque

Most milling performance achieved using solid carbide cutter with a diameter of 16 mm with
the number of teeth z = 4.

Fig. 4.11. Plots of the roughness Ra of the side walls and end slot

from s z when n = 4800 rev / min

graphics, characterizing milling performance

Depending on the feed per tooth shown in Fig. 4.13.

However, when implementing modes providing the greatest

processing performance, should be considered a significant increase

cutting power and torque. Appropriate graphics power

and torque are shown in Fig. 4.14, 4.15.


104

Fig. 4.12. Plots of the roughness Ra of the side walls and

end of the groove when n s z = 0.15 mm / tooth

Fig. 4.13. Dependence milling performance Q of the feed per tooth s z


105

Thus, the power of the machine and the permissible torque on

spindle are limitations that need to be taken into account in the implementation of

modes maximum processing performance.

To achieve optimum performance in the presence of

large metal removal expedient translation of metal-on operations

machining centers with a more powerful spindle, ie conduct

structural optimization process for a particular part,

this will ensure a more productive process with the lack of a stable

vibration and roughness to Ra1,6mkm.

Fig. 4.14. Effect on the feed per tooth cutting power

4.3. machinability study of cutting forces

Among the indicators that define the essence of the workability

cutting refers cutting force in comparison with standard metal,

measured in equal operation conditions [64]. Therefore, in this case,

defined objectives of the study:


106

- determining the workability depending on the cutting forces

Aluminum Alloys V1469 and 01570 compared to AMg6.

indicators:

- components of the cutting forces

- process performance

Fig. 4.15. Effect of feed per tooth in the cutting torque

Equipment for research (Figure 4.16.):

1. Milling machine with CNC mod.6441B

2. Dynamometer UDM-600

3. PC with the signal converter

Cutting tools for research:

The end mill 16 mm diameter Walter z = 3 R2 (Fig. 4.17)

The end mill 16 mm diameter CM TOOLS 16.0 z = 4 (Fig. 4.18)

The studies were conducted at a constant spindle rotation speed

n = 2000 rev / min, minute feed ranged S m = 180 ... 720 mm / min

(S z = 0.03 ... 0.12) [65], a fixed value of the components of the cutting forces at
107

processing elements "wall (Bxt = 1x8 mm), "berm (Bxt = 8x8 mm), the "slot"

(Bxt = 16x8 mm).

Fig. 4.16. Equipment for research

Fig. 4.17. Processing pocket endmill Walter


108

Fig. 4.18. Processing grooves end mill CM TOOLS

After treatment of the experimental results obtained according to

components of cutting forces (Fig. 4.19), and the resultant force (Fig.

4.20) of the minute flow for 3 aluminum alloys in accordance with the

Table 14.

Px, Py, Pz, H

Fig. 4.19. Depending on the components of the cutting forces from the minute feed at

processing 3 when processing aluminum alloys "groove"


109

To estimate the cutting force ratio 3 Aluminum Alloys

AMg6 01570, V1469 in the same conditions, we introduce the force factor

cutting K R ( 4.2), it is the ratio of the cutting force prospective

aluminum alloy to traditional AMg6 (according to schedule on

Fig. 4.20):

KPR persp alloy


. .
/ R AMg 6
. (4.2)

Where P persp.splav - the average value of cutting force promising alloy at

different feeds;

P AMg6 - AMg6 average value of cutting force at different feed rates.

The values of cutting force coefficient K R shown in Table 14.

Fig. 4.20. Depending on the cutting force of the minute feed during processing
element "wall" for 3 aluminum alloys

Thus, the main findings:

1. Carry out a milling of workpieces of 3 aluminum alloys AMg6

01570, V1469 in the same conditions, fixed values of the constituent

cutting forces.
110

2. The milling cutting force at high-strength aluminum

Alloys with respect to the conventional alloy according to AMg6

cutting force coefficient K R ( 4.2) under the same conditions above to 13-27%.

3. According to the results of work obtained depending influence minute feed

on the cutting force for the three aluminum alloys (Fig. 4.19, 4.20).

Table 14.

Comparative properties of aluminum alloys

Mechanical properties
Coefficient of alloys
number Alloy
cutting force TO R AT, 0.2
,%
MPa MPa

1 Aluminum-magnesium alloy 1 300 140 6


AMg6

2 Aluminum-scandium alloy 1.13 373 245 15


01570S

3 Aluminum-lithium alloy B- 1.27 560 540 10


1469

4.4. Investigation resistance carbide cutters and determination

the number of mills for processing of the new ship's hull

Question durability of modern carbide cutters in processing

Aluminum alloys are currently poorly investigated because of the high

tool life and, accordingly, large amount of machine time

the milling cutter.

However, for the treatment of long-term product shell RKT this question

It is relevant, because it is the large assembly unit,

with 1,200 pockets predetermined size (Fig. 4.21). Calculate the time

the milling cutter in the processing of the case.

Initial data in the processing of long-term product shell

CT (taking into account the recommendations of the instrument manufacturer companies, the results of

experiments and optimization results in Chapter 3) accept:


111

Fig. 4.21. Modeling of processing the body part of the new ship

Number of pockets: n = 1200 pieces;

Equipment: large-sized machining center with milling

head 20 kW and spindle speed 10,000

rev / min;

Tool: carbide end mill 16 mm diameter

Cutting data:

Spindle speed: N = 6000 rev / min;

The minute feed: S m = 1200 mm / min.

We calculate the machining time perspective of product shell

CT (4.3):

T mung .
T karmas .
nK xx
6.19 1200 1.05 7800 min (4.3)

WhereT mung .
- the estimated machining time of the housing;
112

T karmas
- pocket
.
machining time, given the rapid moves;

T karmas .
6.19 min ( time calculated in the simulation processing pocket

in ADEM CAD)

K xx- Idling coefficient of machining the workpiece; K xx


1.05 .

n - number of pockets.

Calculate the time of milling in the processing of long-term housing

RKT products (4.4):

T mung .
T karmas .
* n K* xk
6.19 * 0.99 * 1200 7350 min (4.4)

WhereK HC
- Idling coefficient of machining the workpiece; K xk
0.99 .

Estimated time of milling is 7350 minutes, which is

substantial quantity. It should be noted that when a tool breakage

processing large body part is unacceptable as it can

cause irreparable marriage. In this case, such a detail is a long cycle

manufacturing, so in addition to the financial loss for the manufacture of such a

details of this can lead to the disruption of timing of the launch of the spacecraft with

all the ensuing consequences. In addition, automated

production (CNC machines, automatic line) of great importance

acquires the dimensional stability, which determines the time

instrument without loss of precision parts size [66]. Given the large

machine housing processing time, this feature is particularly important.

Thus, it is necessary to evaluate the guaranteed uptime

a tool based on the exclusion of the possibility of failure and save

dimensional stability, and to calculate the required number of cutters for processing

housing. For this purpose, an experiment was conducted stoykostnoy conditions

which simulate the cutter body when processing perspective

products. In addition, the same mill was used in the processing of the model

parts of rocket-space engineering (bracket frame element of EKR) and

for conducting experiments to obtain, depending

the roughness of the cutting modes (grooves, ledges) (Table 15).


113

Table 15.

Hours milling experiments

Obra Botko alloy 015 70


name elements
amount Hours mills, mines:
and details
slots 2.88 m 2.4
ledges 3.24 m 2.7
Bracket 1 children. 37.1
Frame 3 children. 42.0
element EKR 1 children. 107.5
Stoykostnoy experiment 367.5 m 306.3
TOTAL 498 min

Initial data for stoykostnogo experiment:

The end mill 16 mm diameter Master Cut Tool R2,0 z = 2;

Coolant: Emulsion 5-7% -s Blasocut 4000 CF;

Workpiece: 350h300h200 mm, material - aluminum-scandium alloy

01570S;

Spindle speed: n = 6000 rev / min;

Submission: S m = 1200 mm / min;

Width: B = 5 mm;

Depth: t = 8 mm;

Number of passages: 1050.

The total operating time was 498 minutes milling, with the milling cutter

He retained a usable state. To assess the state of the cutter with

an industrial digital camera at a magnification of 200 times

pictures edges and surfaces were obtained (Fig. 4.22).

According to results of image processing on the fixed tool wear

and auxiliary edge radius: wear of the front auxiliary

surface reaches 0.12 mm, the wear on the back surface of the auxiliary

reaches 0.09 mm. Present chipping and spalling values within

wear.
114

Given that the wear on the back surface of the auxiliary is

restriction for finishing bottom of the pocket, and taking into account

wear amount on the front surface of the auxiliary and the total

the condition of the cutting edges, while the mills in the processing enclosure

promising considering the safety factor taking (4.5):

T Fr. .
T exp .
* TOs 498 0.8 398 * min, . (4.5)

WhereT Fr.
- maximum
.
time to replace the cutter;

T exp . - while working with the cutter stoykostnom experiment, after

which is fixed on the wear surfaces and edges;

Bys - a safety factor taking TOs 0.8 .

Fig. 4.22. tool wear


115

We calculate the number of cutters required for machining the housing

new ship (4.6).

N Fr.T . Corp. .
/T Fr. .
7350/398 18.5sht . (4.6)

Where N -Fr.number
.
of cutters for machining of the housing;

T Corp. .
- Estimated processing time body.

Thus, a sufficient number of cutters for machining a

casing is 19 pcs.

Based on the set time of the milling cutter, it should be noted

considering that the results obtained in section 3.4, as stated in [44], where at

occurrence of wear of 0.1 mm shows a sharp increase in the force acting on the

the bottom of the pocket for insertion, suitable for finishing the pocket bottom

use a separate tool that is not involved in the preliminary

sample pocket. Finishing tools with minimal wear

will significantly enhance the stability of the receiving pockets

given geometric parameters.


116

Chapter 5. Testing Results study.

Development of practical recommendations.

5.1. Production verification algorithm and approval

technological documentation in electronic form

The process of harmonization of technical documentation in electronic

form, the development of an algorithm is presented in Chapter 2, passed

testing and implementation in the machining units JSC "MEM"

(Table 16), and it is continuing its implementation in other units

CCI directions.

It should be noted that the testing of the reconciliation process in

electronic form was made on medium complexity parts (2-3

group classifier Table 16) that constitute the 3/4 of the total

number of nomenclatures. The results of this process for 1 and 4 groups are

differ slightly.

The process of harmonization of technical documentation in electronic

It confirmed its effectiveness as based on Windchill PDM-system in

conducting technological preparation of production, but the initial

stage of technical and organizational issues have caused substantial

delay (Table 16).

This is due to including the fact that for the development and operation

automated systems can involve experts in relatively

narrow areas, such as the technology of mechanical engineering, design

software and others, but only in groups that combine

various specialists, working on the same problem [67-68], and

it is not always immediately possible to implement. After setting up the system, Adaptation

Professional and organizational issues in the process of harmonization

electronic design fits into the time frame.


117

Table 16.

Harmonization of technical documentation in electronic form

The actual
End date Standard
difficulty Date of the
Item number matching time, days
Group commencement of negotiation negotiation,
days

1 Nozzle 1 3 03.02.12 04.05.12 21 62

2 Frame 3 03.02.12 27.04.12 21 58

3 Housing 1 3 07.02.12 12.05.12 21 65

4 Housing 2 3 08.02.12 15.04.12 21 45

5 Block 3 3 01.03.12 29.04.12 21 42

6 bracket 2 02.03.12 26.04.12 14 38


1

7 Building 4 2 16.03.12 26.04.12 14 thirty

8 Block 5 3 17.03.12 28.04.12 21 31

9 bracket 3 16.03.12 28.04.12 21 32


2

10 roller 2 06.04.12 15.04.12 14 8

11 Block 6 2 06.04.12 14.04.12 14 7

12 Spigot 2 3 08.04.12 13.05.12 21 24

Cover 1 13 2 03.05.12 18.05.12 14 10

14 Lid 2 2 18.05.12 30.05.12 14 9

15 Hook 2 23.05.12 06.06.12 14 eleven

16 Flange 2 28.05.12 10.06.12 14 10

- Delays - with
delay - on time
118

5.2. Experimental verification of the optimization strategies

EKR processing pocket

The purpose of this test is experimental

definition of plunging strategy that has minimal stress on

the bottom of the same pocket provided processing time.

In experimental studies discussed three typical

Insertion strategies: the contour of the spiral, vertical and spiral (Fig.

5.1) was applied carbide cutter with a diameter of 16 mm Walter H602091-16-

24-2 z = 3, intended for the treatment of aluminum alloys.

processing modes were selected based on the recommended feed and

equal time processing pocket at three different infeed strategies.

Under these conditions, a minimum force recorded during plunging

during insertion strategy twist on a path that was 170N (Fig.

5.2) in the final moment of incision. Effort for helical insertion was

240N.

Fig. 5.1. Strategies and treatment regimens for plunging


119

Figure 5.2. Force values for plunging acting on the bottom of the pocket

Thus, to ensure the lowest force acting at

plunging to the bottom of the pocket, you must apply the Insertion strategy

"Twist on a path."

5.3. Experimental verification of the dependency

roughness of processing modes

Taking into account these recommendations for handling perspective

aluminum alloys developed manufacturing processes, control

programs and models of standard parts processed at the milling OC TOYODA

UG550 (Fig. 5.3).

5.3.1. The item "Element waffle structure"

Machined parts "waffle design element" with slots

dimensions 50x70 mm, wall thickness between the grooves 3 0,2 mm, the size of

the bottom recesses 3 0,2 mm. It served as the blank for the element plate of aluminum-

The lithium alloy 1469-dimensions 300x325x70 mm. Electronic model


120

Details and technological profits for fixing on the table

machining center shown in Fig. 5.4.

Fig. 5.3. Milling machining center TOYODA UG550

Fig. 5.4. "Element waffle design" and the part on the machine table
121

When processing element used tools: cutter end

team diameter of 25 mm Iscar HM90 EAL-D25-C25-L140-15, z = 2; mill

end diameter of 16 mm Master Cut Tool R2 88140 solid carbide,

z = 2. milling modes correspond to the average value of the range,

obtained in 4.2.

Measurement of the roughness of treated surface is

as follows: using a portable profilometer Mitutoyo Surftest

SJ-301 (Fig. 4.1) on each surface of the component 3 held measuring

roughness parameter Ra (similar measurements 4.2.1). Fig. 5.5

numerals indicate the treated surfaces, which held

measuring the roughness parameter Ra. Table 17 shows

Roughness measurements detail surfaces.

As follows from the results of measurements, the roughness of treated

Surface does not exceed Ra1,6mkm that corresponds to the results,

obtained for the mentioned milling cutters in experimental studies

4.2.2.

Figure 5.5. The treated surface roughness measurement items

"Element waffle structure"


122

Table 17.

The results of the roughness measurements of the treated surface of the part

"Element waffle structure"

Roughness Ra, microns


surface
1 measurement 2 measurement 3 dimension

1 0.97 0.85 0.80

2 1.48 1.30 0.80

3 0.92 0.94 0.83

4 1.07 0.72 0.52

5 0.68 1.28 0.78

6 0.63 0.82 0.64

7 0.70 0.83 0.84

8 0.94 0.62 0.78

9 1.01 0.65 0.54

10 0.74 0.83 0.59

5.3.2. Detail "Frame"

Detail of the "frame" is made in the amount of 2 pieces. of aluminum-lithium

B-1469 alloy and aluminum-scandium alloy 01570S. Photo details

mounted on the machine table on the device, shown in Fig.5.6.

When processing the scope of instruments used:

- end mill 25 mm diameter team Iscar HM90 EAL-D25-C25-L140-15 z = 2;

- carbide end mill with a diameter of 16 mm Master Cut Tool R2,0 z = 2;

The relevant parameters section layer cut and the cutting conditions

the processing details of the "frame" shown in Table 18.


123

E-model and machined surfaces to measure

roughness are shown in Figure 5.7.

Figure 5.6. Detail "Frame", installed on the machine table

Table 18.

Cutting data in the processing details of the "frame"

Width
Frequency
cutting Depth Innings Manufacturer-
rotation
Tool (depth Cutting t, s m, Nosta
spindle
slot) B mm mm / min Q, cm 3 / min
n, v / min
mm

mill
3 15 9000 2000 90
25 team

mill 3 5
12000 1200-2400 18-48
whole 16 2 10
124

Figure 5.7. Detail of "frame", to measure the surface roughness

Surface roughness measurements results items are "frame"

It showed that the surface roughness is also within Ra <1 mm, and details

comply with the requirements of the design documentation.

In this way, the results of the experimental verification

found that when TC sufficient rigidity for preliminary

machining of high-strength aluminum alloys to

improve processing efficiency it is advisable to install collective

carbide end mills.

Finishing it is advisable to use one-piece

carbide cutters. Best results were obtained when surface roughness


125

using a 16 mm diameter milling Master Cut Tool z = 2. Hiller has

the best conditions for placing chips in the flutes and

optimal geometry for processing aluminum alloy, as a consequence -

the smallest vibration, and roughness of the processed surface (less

Ra1mkm).

Table 19.

The results of the roughness measurements of the treated surface of the part

"Frame"

Roughness Ra, microns


surface
1 measurement 2 measurement 3 dimension

1 0.15 0.19 0.23

2 0.25 0.34 0.29

3 0.09 0.14 0.12

4 0.15 0.13 0.13

5 0.70 0.82 0.78

6 0.93 0.81 0.97

7 0.37 0.31 0.33

8 0.31 0.33 0.65

5.4. Production and experimental testing

the results of the example manufacturing EKR segment

housing part of prospective products

EKR is made segment of the housing part in a long-term products

actual size of the aluminum alloy plate (01570S) (Fig. 5.8) [69].

Processing performed on the cutting conditions and with the use of strategies

according to Table 20.

Analysis predetermined manufacturability design wafer showed that

to provide a predetermined geometrical parameters of the bottom pocket


126

We need to study the action of cutting forces at the bottom of the finishing infeed

and determination of optimal treatment modes precluding deformation

bottom.

Fig. 5.8. EKR segment in full-size

The study was conducted by calculation Trailer_mill program

(Fig. 5.9) the forces acting on the bottom insertion during finishing, in accordance with

processing modes in Table 20.

Machining time all the pockets on the results of the segment

calculating according to the formula (4.3) is:

T mach. T Karmas. n K xx * 1 05* 1112


6 .19 171 . min

Hours cutter according to the formula (4.4):

T mung .
T karmas
n K. xk
6.19 * 171 * 0.99 1048 min
127

Table 20.

Parameters of the treated structures, strategies and treatment regimens

Parameter Value

cr 7.5

cd 50

Number of pockets 171

treatment strategy Spiral

n, rev / min 6000

S, mm / min 1200

Bxt, mm 5x5

Insertion strategy for finishing


Spiral on a path
bottom

n, rev / min 6000

S, mm / min 1200

Bxt, mm 1h16

insertion angle 9.

The total design force at the end of the milling cutter at


322.7 N
infeed during wear 0.1mm

Estimated elastic deformation of the bottom 0.14 mm

T mung = ( T Karmas. * n) * K xx = ( 171 * 6.19) * 1.05 1112 min

T fr = ( T Karmas. * n) * K xk = ( 6.19 * 171) * 0.99 1048 min

The number of cutters for processing 3 pcs.

Based on the results obtained in section 4.4, taking resistance

cutters for high strength aluminum alloys and a maximum of 400 minutes

flank wear of the end tooth is not more than 0.1 mm. In this way,

given the deterioration in the value of the calculation of Trailer_mill program, we get
128

maximum force on the edge 23: P 223 = 79N, at the edge 56 of P 256 = H 244 (Table

eleven).

Fig. 5.9. Calculation of power in the Trailer_mill, acting on the bottom when inserting

Next, we use this power for loading models with waffle

structure (Fig. 5.10), as close to the wafer

structure segment. Geometric parameters of wafer design

completely correspond structure segment defined yield point for

Aluminum Alloy 01570 = 0.2 245 MPa. This model loading

comparable to the characteristics of the segment model, and at the same time simplifying and

accelerates conduct based on PC CAD CATIA. load model

9 comprises pretreated pockets loading subjected

central pocket, all the side of the model set out in tight seals, bottom

all models in the free state. force application point obtained by

modeling in CAD processing ADEM and has coordinates of each of

pocket walls (44 mm 44 mm).


129

Fig. 5.10. Model for loading a wafer structure

The calculation is performed in the final position with the insertion tool, in

when the cutter reached the finishing bottom of this slide is made

milling depth of 1 mm (the value of allowance). loading platform

is a contact pad and cutter parts when cutting, which is a

taking into account the wear of 0.1 mm and a received original fillet radius of 0.01 mm

It has dimensions of 0.108 mm x 14.7 mm with a yield at the edges of radius (Fig. 5.11).

The analysis showed that the maximum design strain

the bottom of the calculation by finite element method in CATIA CAD (Table 11)

It was not more than 0.14 mm (Fig. 5.12).

Maximum stress (Table 11) consisted of 110 mPa (Fig. 5.13)

that does not exceed the yield strength of the aluminum alloy 01570S = 0.2 245

MPa, i.e. the deformation under these conditions is in the elastic zone.
130

Fig. 5.11. loading platform

Fig. 5.12. Deformation of the bottom when loaded models


131

Fig. 5.13. The stress distribution under load model

Treatment results showed no deformation floor,

geometric dimensions correspond to the design documentation for

segment, the segment for the manufacture took 3 cutter.

Surface roughness is also within the tolerance, that

particularly important in the manufacture of aerospace hardware, since the results

theoretical and experimental studies show what

irregularities formed on the surface of the parts during their processing, are

stress concentrators and are a cause of lowering limit

Stamina [70].
132

EXECUTIVE SUMMARY

1. identified key areas for efficiency

CCI in the manufacture of advanced products and CT revealed their share in

CCI overall complexity: machining technology (32%), the assembly

(19%), test (13%), the design SRT (13%), improvement in CD

Workability (6%), and additive information and technology.

2. Due to the developed and implemented parallel processes and work

in a single information space of the timing of the CCI for new

CT products reduced by 50%; practical realization of the process

coordination and approval of TD showed a reduction process for 40%.

3. The possibility of improving the efficiency in terms of CCI

Design SRT by applying the method of selective laser

sintering: reducing CCI laboriousness in assembly of pipelines made

144 n / h.

4. The developed technique of complex technical CCI

object - the body part with VKO, including the organization of CCI, analysis

technological design, the choice of optimal treatment strategies

Model element of EKR, optimize treatment regimes based

EKR cells exceptions deformation allows CCI body

details with EKR arbitrary size. Recommended ribs coefficients

(TO p < 30) and the bottom (K d < 60) which are technological limitation in

designing parts with EKR.

5. Theoretically substantiated and experimentally proved that

optimal insertion strategy, ensuring minimal impact

the bottom of the pocket of East Kazakhstan region for finishing, is plunging strategy

"Twist on a path."

6. Experimental studies have provided and

use new results in surface roughness in practice


133

Within Ra <1 micron when handling high-strength aluminum alloys,

determine the resistance (400 m) and to calculate the required amount of

carbide cutters for processing large-sized housing pockets

promising products.

7. The results of the thesis have provided development

processes for machining with ASD and beam assembly

pipelines. Matching TD machining is carried out by

algorithm developed in this paper. Obtained in

recommendations on improvement in the processability, and insertion strategies

processing and cutting modes in the manufacture of parts with EKR

used in the issued and implemented in production at JSC "MEM"

technological instruction.
134

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142

ATTACHMENT

A.1. The text of the program Trailer_mill to calculate the forces and contact pressure when
milling aluminum alloy end mills

unit Trailer_mill;
interface
uses
Windows, Messages, SysUtils, Variants, Classes, Graphics, Controls, Forms, Dialogs, StdCtrls,
Math; type

TForm1 = class (TForm)


Label1: TLabel; Label2: TLabel; Label3: TLabel; Label4: TLabel; Edit1: TEdit; Edit2:
TEdit; Edit3: TEdit; Edit4: TEdit; with Button1: TButton; Button2: TButton; Label5: TLabel;
Edit5: TEdit; Memo1: TMemo; Label6: TLabel; Edit6: TEdit; Label7: TLabel; Edit7: TEdit;
Label10: TLabel; Label11: TLabel; Label12: TLabel; Label13: TLabel; Label16: TLabel;
Label17: TLabel; Edit10: TEdit; Edit11: TEdit; Edit12: TEdit; Edit13: TEdit; Edit14: TEdit;
Edit15: TEdit; Edit16: TEdit; Edit18: TEdit; ListBox1: TListBox; Edit19: TEdit; ListBox2:
TListBox; Label8: TLabel; Edit8: TEdit; Label9: TLabel; Edit9: TEdit; Label15: TLabel;
Edit20: TEdit; Button4: TButton; Label19: TLabel; Edit21: TEdit; Label18: TLabel; Edit17:
TEdit; procedure Button1Click (Sender: TObject); procedure Button2Click (Sender:
TObject); procedure ListBox1Click (Sender: TObject); procedure ListBox2Click (Sender:
TObject); procedure Button4Click (Sender: TObject); private {Private declarations} public

{Public declarations} end;


var

Form1: TForm1;
d, z, B, t, w, sm, nn, tau, gam, alfa, ro, r, e, sigmab, delta, sigma02, hz, HB1: real;
marka_OM: string; implementation uses Unit2; {$ R * .dfm}

procedure TForm1.Button1Click (Sender: TObject); // The basic procedure // Description of


variables
var S, kc11, b1, psi0, sz, asr, Pz, zp, Np, v, m: real; str, iznos,
marka_IM: string;
mu1, E1, taup, om_lam, om_omega: real; E2, mu2, im_lam: real;
h, a, gk, a0, da, gamsr, ai, gami: real;
i, N, k, nnn, mm, jj: integer; nuu, k1, bet, Kl, Rc,
omega, rr: real; F1, Pn, mu, l1, sigmam: real; h, Pm, p2, AC, AB: real;
143

AOD, psi, Pmy, Pmz, n1, ftr: real; Rcz, F2, Rcy: real; beti, rri, omegai, sigmami, bi, gi,
alfi, ei: real; Pzy, gam0, P, amax: real; str1: string; File1: TextFile; Ri,
amaxi, psi0i, aai: real; Rj, amaxj, psi0j, aaj, bj, gj, alfj: real;

j, jjj: integer;
F1i, mui, Rczi, Pmi, Pmyi, Pmzi, P2i, ftri, F2i, M23, zpi, Pzi, M12, M34, Pzj: real; Mp: real; gam0t, tau0, betm, fm,
fd: real; szj, fi, fi1: real; n12, N23, n34, BB, de: real; var fii, Rci, Pni, l1i: real;
nu1, beta, M1, qd, Pe0, b_, Td, q1t, q2t, fio, c_, Tp1, Tp2, Tp3, Tp, l2: real; tet: real;
Rcyi, Pyi, pxi, Px23, Py23, Pz23, Ni: real; Pyj, pxj, Px34, Py34, Pz34, Nj, Px, tauz, Pxsum,
M12sum: real; tet0 : Real;
z56, z78, zpj: integer;
ex, Ktet, sigmb20, HB20, im_omega, HV, lam, lamp, Pe, kapa, Lc, nu2, M2, G1, G2, N1_, N2_
. B_l1l2, B_l2l1, ksi: real; Ti, q22, q11, T11, T22, Tpp, Ti_, Tc_, b11: real; a3, b3, a4, b4, a1,
Tc, a2, b2: real; Intr, hzmax, dtau, t0, dhz, hm, Kc, Fcmz, Kver: real;
Omega0, asr0, Ips, dT: real; Kzub, Rj_, M56, M78, Px56, Py56, Pz56, Px78, Py78, Pz78: real; Px12_2, Px23_2, Px12:
real; P212, P212_2, P223, P223_2, P234, P256, P278: real; Sp, Fo, taur: real; Teta, Teta2: real;
x, y: real; a_plast, h_plast, Kw_, wmax, KI: real;
// Auxiliary input function
function FormatTranslate (var stroka: string): real; var t: real;
begin

if pos ( ',', stroka) <> 0 then DecimalSeparator: = ',' else DecimalSeparator: =; '.' t: =
StrToFloat (stroka); FormatTranslate: = t; end; // The properties of aluminum alloys, the
properties of hardmetals

Procedure OM_Svoistva (ToC: real); // Properties of Al-alloys and CU begin

if marka_OM = ( 'AMg6') then begin mu1: = 0.33; E1: = 71; {GPa} HB1: = 850; {MPa}
sigmab: = 300; sigma02: = 140; delta: = 6; sigmab: = 308.7 * exp
(-0.0014 * ToC); taup: = 0.95 * sigmab; {MPa} HB1: = sigmab /
0.35; om_lam: = 0.29; {kal / cm.c.grad} om_omega: = 0.53; {cm2 /
c} end;

if marka_OM = ( 'B1469') then begin mu1: = 0.33; E1: = 79; {GPa} // HB1: = 850; {MPa}
sigmab: = 574; sigma02: = 550; delta: = 8.8; sigmab: = 590.3 *
exp (-0.0014 * ToC); taup: = 0.95 * sigmab; {MPa} HB1: = sigmab
/ 0.35; om_lam: = 0.29; {kal / cm.c.grad} om_omega: = 0.53; {cm2
/ c} end;

if marka_OM = ( '01570C') then begin mu1: = 0.33; E1: = 78; {GPa}


sigmab: = 383; sigma02: = 265; delta: = 14; sigmab: = 393.8 *
exp (-0.0014 * ToC); taup: = 0.95 * sigmab; {MPa} HB1: =
sigmab / 0.35; om_lam: = 0.29; {kal / cm.c.grad} om_omega: =
0.53; {cm2 / c} end;

// ------------------------------------------------ ------------------------ if marka_IM = (


'BK6M') then begin E2 = 640; mu2: = 0.29;
144

im_lam: = 0.145; {kal / cm with grad)}


im_omega: = 0.246; // cm2 / c HV: =
(13448.14-8.69 * ToC); end;

if marka_IM = ( 'BK8') then begin E2 = 610; mu2: = 0.29;


im_lam: = 0.130; im_omega: = 0.246; //
cm2 / c HV: = (12976.86-9.224 * ToC); end;

end; // Auxiliary routine for calculating temperature

procedure ApprocsimB;
begin
if (l1 / l2 = 0) or (l2 / l1 = 0) then begin B_l1l2: = 2.93; B_l2l1: = 2.93; end; // .........

end; {AppprocsimB} // The calculation for the


radius of the edge
procedure Sigma_Radius (ei, bi, gi, alfi, ai: real); begin jj: =
0; Td: = 20; T11: = 20; T22: = 20;
if (ai> = 0.01) then begin
REPEAT inc (jj);
// chislo ciklov vrezaniya
OM_Svoistva (Td); // uchet vliyaniya temperaturi na svoistva OM
nuu: = (1-mu1 * mu1) / E1 + (1-mu2 * mu2) / E2; k1: = 1;
beti: = arctan ((cos (gi) + sin (gi)) / (1.08 * k1 * (sqrt (sqrt (nuu * E1 * bi / ai))) + cos (gi) -sin (gi))); rri: = ArcTan2 (Tan
(beti-gi), Tan (beti-gi) +2); omegai: = pi / 4 + rri-beti;
{Actions} angle
Kl: = cos (gi) * cos (beti) / sin (beti) + sin (gi); Rci: = taup * ai *
bi / sin (beti) / cos (beti + omegai); Pni: = Rci * cos (omegai +
gi); F1i: = Rci * sin (omegai + gi); mui: = F1i / Pni;

Rczi: = Rci * cos (omegai); Rcyi: = Rci * sin (omegai); l1i: = 2 * ai / sin
(beti); // dlina kontakta strujki
l1: = l1i;
sigmami: = 2 * Pni / (l1i * bi);
if (iznos = 'no') then begin Pmi: = sigmami * AC * bi; // Power on the cutting edge
AOD: = 1/2 * (alfi + pi / 2-abs (gk)); // hz: = 0; psi: = pi /
2-abs (gk) -AOD;
Pmyi: = Pmi * cos (psi); Pmzi: = Pmi * sin (psi); l2: = AC;
end;

if (iznos = 'yes') then begin


Pmi: = sigmami * AB * bi; // hz: = hzmax;
AOD: = 1/2 * (pi / 2-abs (gk)); psi: = pi
/ 2-abs (gk) -AOD;
Pmyi: = Pmi * cos (psi); Pmzi: = Pmi * sin (psi); n1: = 1; P2i:
= sigmami * hz / n1 * bi;
l2: = AB + hz;
begin
if T22> 1000 then betm: = 0.05;
145

if T22 <= 1000 then begin {approximation according to Granovsky,


Kostetskii, Makarov, Schuster}
x: = 2.105 * 1e-3 * T22;
y: = 2.6048 * Power (x, 6) -19.737 * Power (x, 5) + 58.653 * Power (x, 4) -
87.216 * Power (x, 3) +
68.532 * Power (x, 2) -27.473 * x + 5.3033; betm: =
0.260 * y + 0.053; end;

if T22 <= 600 then tau0: = 120;


if (T22> 600) and (T22 <= 1000) then tau0: = 252-0.19 * T22; if T22> 1000
then tau0: = 50; end;

fm: = tau0 / HB1 + betm; //molekul.sostavl


fd: = 0; //deform.sostavl
ftri: = fm + fd; // koef. treniya na zadnee poverxnosti
F2i: = P2i * ftri;
end;
// Calculation of cutting temperature
a: = ai; b: = bi; bet: = beti; F1: = F1i; F2: = F2i; Pmz: = Pmzi; v: = pi * 2 * Ri *
nn / 1000; Pz: = (Rczi + Pmzi + F2i);

qd: = 3.9 / a / b * sin (bet) * (Pz / 9.81 * v-F1 / 9.81 * v / Kl -Pmz / 9.81 * v -F2 / 9.81 * v); //power
heat deformation
Pe0: = 1/6 * v * a / om_omega / sin (bet); b _: = 1 / (1
+ 1.5 * Kl / sqrt (Pe0));
Td: = 0.6 * om_omega * Kl / om_lam / v * b_ * qd; // Low shear plane q1t: = 5.85 * F1 / 9.81 * v /
l1 / b / Kl; // heat capacity friction on the front
{{Intensity of the heat flux on the rear surface} q2t: = 3.9 * F2 / 9.81 * v /
b / l2;
lam: = om_lam; om_omega: = om_omega;
lamp: = im_lam; {Thermal conductivity instrum.materiala} fio: = 1.33 * Power
(10, -2) * v * a * a / om_omega / 2 / d * 2;
if (fio <= 0.15) and (fio> = 0.001) then c _: = 0.23 * exp (-40 * sqr (0.15-fio)); if (fio <= 2) and
(fio> 0.15) then c _: = 0.23 * exp (-3.5 * sqr (-0.15 + fio)); if (fio> 2) then begin

Form1.Memo1.Lines.Add ( 'error criterion based fio, fio> 2' + FloatToStrF (fio,


FFGeneral, 6,5)); halt (1);
end;
if (fio <0.001) then c _: = 0; Pe: = 1/6 * v *
l1 / om_omega / Kl; kapa: = sqr (kl * a / l1)
* Pe;
if (kapa <= 1.2) and (kapa> = 0.1) then Lc: = 1.066 / Power (kapa, 0.35); if (kapa> 1.2)
then Lc: = 1; if kapa <0.1 then Lc: = 1; {85,84} ksi: = l2 / 2 / a * sin (bet) / cos (bet);

Ti _: = sqrt (1 + ksi) -sqrt (ksi);


----------- {}
nu1: = b / l1; nu2: = b / l2; beta: = pi / 2- (gam + alfa); // rad
if nu1> = 1 then M1: = (4.88 + 2.64 * Power (nu1,0.5) * logN (10, nu1)) * Power (beta * 180 / pi, -0.85); if nu1 <1 then M1: =
(4.88 + 3.92 * Power (nu1,0.27) * logN (10, nu1)) * Power (beta * 180 / pi, -0.85); if nu2> = 1 then M2: = (4.88 + 2.64 * Power
(nu2,0.5) * logN (10, nu2)) * Power (beta * 180 / pi, -0.85);
146

if nu2 <1 then M2: = (4.88 + 3.92 * Power (nu2,0.27) * logN (10, nu2)) * Power (beta * 180 / pi, -
0.85); {91}
if nu1> = 1, then G1: = 0.04 + 0.02 * Power (nu1,0.6) * logN (10, nu1); if nu2> = 1 then
G2: = 0.04 + 0.02 * Power (nu2,0.6) * logN (10, nu2); if nu1 <1, then G1: = 0.04 + 0.028 *
Power (nu1,0.22) * logN (10, nu1); if nu2 <1 then G2: = 0.04 + 0.028 * Power (nu2,0.22) *
logN (10, nu2); ApprocsimB;

N1 _: = G1 * B_l2l1; N2 _: = G2 * B_l1l2; {88} a3:


= M1 / lamp * l1;
b3: = N2_ / lamp * l2; {T1: =
a3 * q1 + b3 * q2; T1 = Tc}

{89} a4: = M2 / lamp * l2;


b4: = N1_ / lamp * l1; {T2: =
a4 * q2 + b4 * q1} {T2 = Ti}

a1: = (1 + c _) * Td + 0.142 * sqrt (om_omega) / lam * Lc * sqrt (kl * l1 / v) * q1t; b11: = 0.142 * sqrt
(om_omega) / lam * Lc * sqrt (kl * l1 / v) * 1.3; {(80)} {Tc: = (1 + c _) * Td + 0.142 * sqrt (omega) / lam * Lc * sqrt
(kl * l1 / v) * (q1t-1.3 * q1);
Tc: = a1-b11 * q1;}
{Contact area temperature parts and the cutter} a2: = (1 + c _) * Td * Ti_ +
0.1 * sqrt (om_omega * l2 / v) / lam * q2t; b2: = 0.1 * sqrt (om_omega * l2 / v)
/lam*1.82;
{83} {Ti: = (1 + c _) * Td * Ti_ + 0.1 * sqrt (omega * hz / v0) / lam * (q2t-1.82 * q2);
Ti: = a2-b2 * q2;}
{------ solution of equations}
q22: = (a2 * a3 + a2 * b11-a1 * b4) / (a4 * b11 + a3 * a4-b4 * b3 + a3 * b2 + b11 * b2); q11: = (a1-b3 *
q22) / (a3 + b11);
{On the front surface temperature ----} T11: = a3 * q11 +
b3 * q22; Tc _: = a1-b11 * q11; {On the back surface
temperature ----} T22: = a4 * q22 + b4 * q11; Ti: = a2-b2 *
q22; Tpp: = (T11 * l1 + T22 * l2) / (l1 + l2); Td: = Td; UNTIL

jj = 10; // (Ktet <= 0.001);


end else
begin Form1.Memo1.Lines.Add ( 'ai <h'); sigmami: = 0; beti: = 0;
Rczi: = 0; Pmzi: = 0; F2i: = 0; end;
end; // Calculation for mechanical tooth

procedure Sigma_Torec (ei, bi, gi, alfi, ai: real); // dlya torcevix zubiev begin jj: = 0; Td:
= 20; T11: = 20; T22: = 20;
if (ai> = 0.01) then begin
REPEAT inc (jj);

OM_Svoistva (20); nuu: = (1-mu1 * mu1) / E1 + (1-mu2 * mu2) / E2; k1: = 1;


beti: = arctan ((cos (gi) + sin (gi)) / (1.08 * k1 * (sqrt (sqrt (nuu * E1 * bi / ai))) + cos (gi) -sin (gi))); rri: = ArcTan2 (Tan
(beti-gi), Tan (beti-gi) +2); omegai: = pi / 4 + rri-beti;
{Actions} angle
Kl: = cos (gi) * cos (beti) / sin (beti) + sin (gi); Rci: = taup * ai * bi
/ sin (beti) / cos (beti + omegai);
147

Pni: = Rci * cos (omegai + gi); F1i: =


Rci * sin (omegai + gi); mui: = F1i /
Pni;
Rczi: = Rci * cos (omegai); Rcyi: = Rci * sin (omegai); l1i: = 2 * ai /
sin (beti); l1: = l1i;

sigmami: = 2 * Pni / (l1i * bi);


if (iznos = 'no') then begin Pmi: = sigmami * AC * bi; // Power on the cutting edge
AOD: = 1/2 * (alfi + pi / 2-abs (gk)); // hz: = 0; psi: = pi /
2-abs (gk) -AOD;
Pmyi: = Pmi * cos (psi); Pmzi: = Pmi * sin (psi); l2: = AC;
end;

if (iznos = 'yes') then begin


Pmi: = sigmami * AB * bi; // hz: = hzmax;
AOD: = 1/2 * (pi / 2-abs (gk)); psi: = pi
/ 2-abs (gk) -AOD;
Pmyi: = Pmi * cos (psi); Pmzi: = Pmi * sin (psi); l2: = AB +
hz;
n1: = 1; P2i: = sigmami * hz / n1 * bi;
begin
if T22> 1000 then betm: = 0.05; if T22
<= 1000 then begin
x: = 2.105 * 1e-3 * T22;
y: = 2.6048 * Power (x, 6) -19.737 * Power (x, 5) + 58.653 * Power (x, 4) -
87.216 * Power (x, 3) +
68.532 * Power (x, 2) -27.473 * x + 5.3033; betm: =
0.260 * y + 0.053; end;

if T22 <= 600 then tau0: = 120;


if (T22> 600) and (T22 <= 1000) then tau0: = 252-0.19 * T22; if T22> 1000
then tau0: = 50; end;

fm: = tau0 / HB1 + betm; //molekul.sostavl


fd: = 0; //deform.sostavl
ftri: = fm + fd; // koef. treniya na zadnee poverxnosti
F2i: = P2i * ftri;
end;
a: = ai; b: = bi; bet: = beti; F1: = F1i; F2: = F2i; Pmz: = Pmzi; v: = pi * 2 * Ri *
nn / 1000; Pz: = (Rczi + Pmzi + F2i);

qd: = 3.9 / a / b * sin (bet) * (Pz / 9.81 * v-F1 / 9.81 * v / Kl -Pmz / 9.81 * v -F2 / 9.81 * v); //power
heat deformation
Pe0: = 1/6 * v * a / om_omega / sin (bet); b _: = 1 / (1
+ 1.5 * Kl / sqrt (Pe0));
Td: = 0.6 * om_omega * Kl / om_lam / v * b_ * qd; // Low plane
shift
q1t: = 5.85 * F1 / 9.81 * v / l1 / b / Kl; // heat capacity of the friction in the
front
{{Intensity of the heat flux on the rear surface} q2t: = 3.9 * F2 / 9.81 * v /
b / l2;
148

lam: = om_lam; om_omega: = om_omega; lamp: = im_lam; {thermal conductivity


instrum.materiala}
fio: = 1.33 * Power (10, -2) * v * a * a / om_omega / 2 / d * 2;
{C_ - koef.uchityv.podogrev surface layers of the material of which
formed chips}
if (fio <= 0.15) and (fio> = 0.001) then c _: = 0.23 * exp (-40 * sqr (0.15-fio)); if (fio <= 2) and
(fio> 0.15) then c _: = 0.23 * exp (-3.5 * sqr (-0.15 + fio)); if (fio> 2) then begin

Form1.Memo1.Lines.Add ( 'error criterion based fio, fio> 2' + FloatToStrF (fio,


FFGeneral, 6,5)); halt (1);
end;
if (fio <0.001) then c _: = 0; Pe: = 1/6 * v *
l1 / om_omega / Kl; kapa: = sqr (kl * a / l1)
* Pe;
if (kapa <= 1.2) and (kapa> = 0.1) then Lc: = 1.066 / Power (kapa, 0.35); if (kapa> 1.2)
then Lc: = 1; if kapa <0.1 then Lc: = 1; {85,84} ksi: = l2 / 2 / a * sin (bet) / cos (bet);

Ti _: = sqrt (1 + ksi) -sqrt (ksi);


nu1: = b / l1; nu2: = b / l2; beta: = pi / 2- (gam + alfa); // rad
if nu1> = 1 then M1: = (4.88 + 2.64 * Power (nu1,0.5) * logN (10, nu1)) * Power (beta * 180 / pi, -0.85); if nu1 <1 then M1: =
(4.88 + 3.92 * Power (nu1,0.27) * logN (10, nu1)) * Power (beta * 180 / pi, -0.85); if nu2> = 1 then M2: = (4.88 + 2.64 * Power
(nu2,0.5) * logN (10, nu2)) * Power (beta * 180 / pi, -0.85);
if nu2 <1 then M2: = (4.88 + 3.92 * Power (nu2,0.27) * logN (10, nu2)) * Power (beta * 180 / pi, -
0.85); {91}
if nu1> = 1, then G1: = 0.04 + 0.02 * Power (nu1,0.6) * logN (10, nu1); if nu2> = 1 then
G2: = 0.04 + 0.02 * Power (nu2,0.6) * logN (10, nu2); if nu1 <1, then G1: = 0.04 + 0.028 *
Power (nu1,0.22) * logN (10, nu1); if nu2 <1 then G2: = 0.04 + 0.028 * Power (nu2,0.22) *
logN (10, nu2); ApprocsimB;

N1 _: = G1 * B_l2l1; N2 _: = G2 * B_l1l2; {88} a3:


= M1 / lamp * l1;
b3: = N2_ / lamp * l2; {T1: =
a3 * q1 + b3 * q2; T1 = Tc}

{89} a4: = M2 / lamp * l2;


b4: = N1_ / lamp * l1; {T2: =
a4 * q2 + b4 * q1} {T2 = Ti}

a1: = (1 + c _) * Td + 0.142 * sqrt (om_omega) / lam * Lc * sqrt (kl * l1 / v) * q1t; b11: = 0.142 * sqrt
(om_omega) / lam * Lc * sqrt (kl * l1 / v) * 1.3; {(80)} {Tc: = (1 + c _) * Td + 0.142 * sqrt (omega) / lam * Lc * sqrt
(kl * l1 / v) * (q1t-1.3 * q1);
Tc: = a1-b11 * q1;}
{Contact area temperature parts and the cutter} a2: = (1 + c _) * Td * Ti_ +
0.1 * sqrt (om_omega * l2 / v) / lam * q2t; b2: = 0.1 * sqrt (om_omega * l2 / v)
/lam*1.82;
{83} {Ti: = (1 + c _) * Td * Ti_ + 0.1 * sqrt (omega * hz / v0) / lam * (q2t-1.82 * q2);
Ti: = a2-b2 * q2;}
{------ solution of equations}
q22: = (a2 * a3 + a2 * b11-a1 * b4) / (a4 * b11 + a3 * a4-b4 * b3 + a3 * b2 + b11 * b2); q11: = (a1-b3 *
q22) / (a3 + b11);
{On the front surface temperature ----}
149

T11: = a3 * q11 + b3 * q22; Tc _: = a1-b11 * q11; {On the


back surface temperature ----} T22: = a4 * q22 + b4 * q11;
Ti: = a2-b2 * q22; Tpp: = (T11 * l1 + T22 * l2) / (l1 + l2); Td:
= Td;
// Td ne zavisit ot chiklov
UNTIL jj = 10; // (Ktet <= 0.001);
end else
begin Form1.Memo1.Lines.Add ( 'ai <h'); sigmami: = 0; beti: = 0;
Rczi: = 0; Pmzi: = 0; F2i: = 0; end;
end; // The calculation for a cylindrical edge

procedure Sigma_Cilindr; var i:


integer; Begin

v: = pi * d * nn / 1000; // m / min a: = asr;

IF a <0.01 then Form1.Memo1.Lines.Add ( 'amax <h') ELSE //


amax> h BEGIN N: = 10;

da: = (ah) / N; gamsr: = 0; for i: = 1


to N do begin ai: = h + i * da;
if ai <a0 then gami: = arcsin ((ai-ro) / ro) else gami:
= gam0; gamsr: = gamsr + gami; end;

gam: = gamsr / N; // take the average value of the front. angle if (BB> r) then

BEGIN jj: = 0; // Td: = 20; T11: = 20; T22: = 20;


// ----------------------- cikli chisla vrezanii ---------------------- --------------- REPEAT inc (jj);

// chislo ciklov vrezaniya


OM_Svoistva (Td); // uchet vliyaniya temperaturi na svoistva OM
b: = b1; // full length of the edge
nuu: = (1-mu1 * mu1) / E1 + (1-mu2 * mu2) / E2 k1: = 1
bet: = ArcTan ((cos (gam) + sin (gam)) / (1.08 * k1 * (sqrt (sqrt (nuu * E1 * b / a))) + cos (gam) -sin (gam))); rr: = ArcTan2 (Tan
(bet-gam), Tan (bet-gam) +2); // popravka, Rozenberg str.84
omega: = pi / 4 + rr-bet; Angle {Actions} {}
shrinkage ratio
Kl: = cos (gam) * cos (bet) / sin (bet) + sin (gam); {On
the front surface} {H} Rc: = taup * a * b / sin (bet) / cos
(bet + omega); {} Struzhkoobrazovanija
F1: = Rc * sin (omega + gam); // treniya na perednei
Pn: = Rc * cos (omega + gam); // normalnaya
mu: = F1 / Pn; // koef. treniya na perednee poverxnosti
l1: = 2 * a / sin (bet); // dlina kontakta strujki
// --------------------------------- sigmam: =
2 * Pn / (l1 * b); // max davlenie na reg kromke
Rcz: = Rc * cos (omega); Rcy: = Rc *
sin (omega); v: = pi * d * nn / 1000; // m
/ min P2: = 0;
150

if (iznos = 'no') then begin Pm: = sigmam * AC * b; // Power on the cutting edge
AOD: = 1/2 * (alfa + pi / 2-abs (gk)); // hz: = 0; psi: = pi /
2-abs (gk) -AOD;
Pmy: = Pm * cos (psi); Pmz: = Pm * sin (psi); l2: = AC;
end;

if (iznos = 'yes') then begin Pm: = sigmam * AB * b; // hz: = hzmax;


AOD: = 1/2 * (pi / 2-abs (gk)); psi: = pi
/ 2-abs (gk) -AOD;
Pmy: = Pm * cos (psi); Pmz: = Pm * sin (psi); l2: = AB +
hz;
n1: = 1; P2: = sigmam * hz / n1 * b;
begin
if T22> 1000 then betm: = 0.05;
if T22 <= 1000 then begin {approximation according to Granovsky,
Kostetskii, Makarov, Schuster}
x: = 2.105 * 1e-3 * T22;
y: = 2.6048 * Power (x, 6) -19.737 * Power (x, 5) + 58.653 * Power (x, 4) -
87.216 * Power (x, 3) +
68.532 * Power (x, 2) -27.473 * x + 5.3033; betm: =
0.260 * y + 0.053; end;

if T22 <= 600 then tau0: = 120;


if (T22> 600) and (T22 <= 1000) then tau0: = 252-0.19 * T22; if T22> 1000
then tau0: = 50; end;

fm: = tau0 / HB1 + betm; //molekul.sostavl


fd: = 0; //deform.sostavl
ftr: = fm + fd; // koef. treniya na zadnee poverxnosti F2: = P2 *
ftr; end;

Pz: = (Rcz + Pmz + F2); a: =


asr; // asr; Temperature calculation of average
thickness
qd: = 3.9 / a / b * sin (bet) * (Pz / 9.81 * v-F1 / 9.81 * v / Kl -Pmz / 9.81 * v -F2 / 9.81 * v); //power
heat deformation
Pe0: = 1/6 * v * a / om_omega / sin (bet); b _: = 1 / (1
+ 1.5 * Kl / sqrt (Pe0));
Td: = 0.6 * om_omega * Kl / om_lam / v * b_ * qd; // Low plane
shift
q1t: = 5.85 * F1 / 9.81 * v / l1 / b / Kl; // heat capacity of the friction in the
front
{{Intensity of the heat flux on the rear surface} q2t: = 3.9 * F2 / 9.81 * v /
b / l2;
lam: = om_lam; om_omega: = om_omega; lamp: = im_lam; {thermal conductivity
instrum.materiala}
fio: = 1.33 * Power (10, -2) * v * a * a / om_omega / 2 / d * 2;
{C_ - koef.uchityv.podogrev surface layers of the material of which
formed chips}
if (fio <= 0.15) and (fio> = 0.001) then c _: = 0.23 * exp (-40 * sqr (0.15-fio)); if (fio <= 2) and
(fio> 0.15) then c _: = 0.23 * exp (-3.5 * sqr (-0.15 + fio)); if (fio> 2) then begin
151

Form1.Memo1.Lines.Add ( 'error criterion based fio, fio> 2' + FloatToStrF (fio,


FFGeneral, 6,5)); halt (1);
end;
if (fio <0.001) then c _: = 0; Pe: = 1/6 * v *
l1 / om_omega / Kl; kapa: = sqr (kl * a / l1)
* Pe;
if (kapa <= 1.2) and (kapa> = 0.1) then Lc: = 1.066 / Power (kapa, 0.35); if (kapa> 1.2)
then Lc: = 1; if kapa <0.1 then Lc: = 1; {85,84} ksi: = l2 / 2 / a * sin (bet) / cos (bet);

Ti _: = sqrt (1 + ksi) -sqrt (ksi);


----------- {}
nu1: = b / l1; nu2: = b / l2; beta: = pi / 2- (gam + alfa); // rad
if nu1> = 1 then M1: = (4.88 + 2.64 * Power (nu1,0.5) * logN (10, nu1)) * Power (beta * 180 / pi, -0.85); if nu1 <1 then M1: =
(4.88 + 3.92 * Power (nu1,0.27) * logN (10, nu1)) * Power (beta * 180 / pi, -0.85); if nu2> = 1 then M2: = (4.88 + 2.64 * Power
(nu2,0.5) * logN (10, nu2)) * Power (beta * 180 / pi, -0.85);
if nu2 <1 then M2: = (4.88 + 3.92 * Power (nu2,0.27) * logN (10, nu2)) * Power (beta * 180 / pi, -
0.85); {91}
if nu1> = 1, then G1: = 0.04 + 0.02 * Power (nu1,0.6) * logN (10, nu1); if nu2> = 1 then
G2: = 0.04 + 0.02 * Power (nu2,0.6) * logN (10, nu2); if nu1 <1, then G1: = 0.04 + 0.028 *
Power (nu1,0.22) * logN (10, nu1); if nu2 <1 then G2: = 0.04 + 0.028 * Power (nu2,0.22) *
logN (10, nu2); ApprocsimB;

N1 _: = G1 * B_l2l1; N2 _: = G2 * B_l1l2; {88} a3:


= M1 / lamp * l1;
b3: = N2_ / lamp * l2; {T1: =
a3 * q1 + b3 * q2; T1 = Tc}

{89} a4: = M2 / lamp * l2;


b4: = N1_ / lamp * l1; {T2: =
a4 * q2 + b4 * q1} {T2 = Ti}

a1: = (1 + c _) * Td + 0.142 * sqrt (om_omega) / lam * Lc * sqrt (kl * l1 / v) * q1t; b11: = 0.142 * sqrt
(om_omega) / lam * Lc * sqrt (kl * l1 / v) * 1.3; {(80)} {Tc: = (1 + c _) * Td + 0.142 * sqrt (omega) / lam * Lc * sqrt
(kl * l1 / v) * (q1t-1.3 * q1);
Tc: = a1-b11 * q1;}
{Contact area temperature parts and the cutter} a2: = (1 + c _) * Td * Ti_ +
0.1 * sqrt (om_omega * l2 / v) / lam * q2t; b2: = 0.1 * sqrt (om_omega * l2 / v)
/lam*1.82;
{83} {Ti: = (1 + c _) * Td * Ti_ + 0.1 * sqrt (omega * hz / v0) / lam * (q2t-1.82 * q2);
Ti: = a2-b2 * q2;}
{------ solution of equations}
q22: = (a2 * a3 + a2 * b11-a1 * b4) / (a4 * b11 + a3 * a4-b4 * b3 + a3 * b2 + b11 * b2); q11: = (a1-b3 *
q22) / (a3 + b11);
{On the front surface temperature ----} T11: = a3 * q11 + b3
* q22; Tc _: = a1-b11 * q11; {On the back surface
temperature ----} T22: = a4 * q22 + b4 * q11; Ti: = a2-b2 *
q22; Tpp: = (T11 * l1 + T22 * l2) / (l1 + l2); a: = amax;

// return the maximum value


UNTIL jj = 10; //(Ktet<=0.001); Fo: = 100 *
im_omega * taur / Sqr (l1); // Furie
152

Tr_mill (ex, Fo); M1: =


M1 * Sp; // correction processing on the character preryvmsty
Reznikova
Teta: = 0.142 * sqrt (om_omega) / lam * sqrt (Kl * l1 / v) * q1t + (1 + c _) * Td; Teta2: = M1 * l1 /
lamp + 0.148 * sqrt (om_omega) / lam * sqrt (Kl * l1 / v); Teta: = sqr (l1) * M1 / lamp / (l1 + l2) *
Teta / Teta2; // Reznikov (95) str. 85 bez vliyaniy
temperaturi zadnei pjverxnosti
OM_Svoistva (Teta); KI: =
0.0026; // according to [Guzeyeva]
if marka_OM = ( 'AMg6') then Intr: = KI * 1.03e7 * Power (v / 60 / HV, 2.47); if marka_OM = (
'01570C') then Intr: = KI * 1.03e7 * Power (v / 60 / HV, 2.47); if marka_OM = ( 'B1469') then Intr:
= KI * 1.03e7 * Power (v / 60 / HV, 2.47); If (HV <100) then begin Intr: = 10;
// low values HV calculation
terminated
writeln (File1, 'Small values HV, calculation discontinued');
Form1.Memo1.Lines.Add ( 'Small value HV, calculation
terminated ');
END; END; End; // The basic design of the
program

begin // Calculation
Form1.Memo1.Visible: = True;
Form1.Memo1.Clear; str1: =
(Edit9.Text);
assignFile (File1, str1); rewrite (File1);
writeln (File1, 'Pr Trailer_mill - calculation of forces and contact pressure for the end mill.'); writeln (File1,
'Authors: S.V.Gruby, AM Zaitsev, 2013-2015'); Form1.Memo1.Lines.Add ( 'Trailer_mill Program');

Form1.Memo1.Lines.Add ( 'Calculating forces and contact pressure to the end mill');


Form1.Memo1.Lines.Add ( 'Authors: S.V.Gruby, AM Zaitsev, 2013-2015'); writeln (File1, ''); // Data
input

str: = Edit1.Text; d: = FormatTranslate (str);


str: = Edit3.Text; BB: = FormatTranslate (str);
str: = Edit4.Text; t: = FormatTranslate (str);
str: = Edit11.Text; w: = FormatTranslate (str); // grad w: = w *
pi / 180; // rad
str: = Edit7.Text; nn: = FormatTranslate (str); // ob / min
str: = Edit6.Text; sz: = FormatTranslate (str); sm: = sz * z * nn; // mm / min
str: = Edit8.Text; tau: = FormatTranslate (str) * pi / 180; // rad
str: = Edit10.Text; gam: = FormatTranslate (str) * pi / 180; gam0: = gam; // rad str: = Edit5.Text;
alfa: = FormatTranslate (str) * pi / 180; // rad str: = Edit12.Text; ro: = FormatTranslate (str); str: =
Edit15.Text; r: = FormatTranslate (str);

str: = Edit16.Text; fi: = FormatTranslate (str) * pi / 180; e: = pi-fi; // rad str: = Edit21.Text;
fi1: = FormatTranslate (str) * pi / 180; // rad
str: = Edit13.Text; hz: = FormatTranslate (str); // mm str: = Edit17.Text;
hzmax: = FormatTranslate (str); // mm Kzub: = 0.63;

Form1.ListBox1.Clear;
Form1.ListBox1.Items.Add ( 'AMg6');
153

Form1.ListBox1.Items.Add ( '01570C');
Form1.ListBox1.Items.Add ( 'B1469');
marka_OM: = Edit18.Text;
//---------------------------------------Form1.ListBox2.Clear;

Form1.ListBox2.Items.Add ( 'BK6M');
Form1.ListBox2.Items.Add ( 'BK8'); marka_IM:
= Edit19.Text;
//-----------------------------------iznos:=Edit14.Text;
str: = Edit2.Text;
z: = FormatTranslate (str);
// ---------------------------------------- k: = 5;
// the number of sites on the radius of the
// Calculation
writeln (File1, 'd =', d: 4: 1, '; z =', z: 4: 1, '; B =', BB: 4: 1, '; t =', t: 4: 1 ); sm: = sz * z * nn;

writeln (File1, 'sm, mm / min =', sm: 4: 1, '; sz, mm / zub =', sz: 3: 3, '; Q, cm3 / min =', sm * BB * t / 1000: 5: 1); writeln (File1, 'n, ob /
min =', nn: 4: 1); writeln (File1, 'tau, grad =', tau * 180 / pi: 4: 1); writeln (File1, 'r, mm =', r: 4: 1); Tp: = 20; Td: = 20; OM_Svoistva (Td);

writeln (File1, 'marka_OM =', marka_OM, 'sigmab =', sigmab: 4: 1, 'HB1 =', HB1: 4: 1); writeln (File1,
'marka_IM =', marka_IM); v: = pi * d * nn / 1000;
// m / min
writeln (File1, '-------- 1). chip and normal pressure ') Calculation of the force; writeln (File1, '-------- 1.1). In
the horizontal plane - a cylindrical edge 12 '); Form1.Memo1.Lines.Add ( '---------------- --------------------
helical edge 12') ; // ------- cylindrical tooth

if (w> 0) then begin hh: = 2 * pi * d * Cotan (w); // shag


S: = sqrt (sqr (d / 2) + sqr (hh / 2 / pi)) * tan (w) / d * (BB-r); // dlina dugi na
cilindrich. chasti
b1: = S; // shirina sreza odnogo zuba
end else b1: = BB;

if (t> = d / 2) then psi0: = pi / 2 // 1st tooth stops at the maximum thickness of the slice
else psi0: = ArcCos ((d / 2-t) / (d / 2)); sm: = sm;
h: = ro / 3;

gk: = - arcsin ((ro-h) / ro); a0: = ro * (1 + sin (gam)) - h;


AC: = ro * ((pi / 2-abs (gk)) + alfa); AB: = ro * (pi / 2-abs (gk));
if (t <d / 2) then tet: = arccos (+ cos (tau) * sin (psi0) / sqrt (sqr (sin (tau)) + sqr (cos (tau)) * sqr (sin (psi0)) )) // mejdu vektorom Cxy
i osu Y
else tet: = tau; amax: = sz *
cos (tau) * sin (psi0);
if (t> d / 2) then Omega0: = pi / 2 + Arcsin ((td / 2) / (d / 2))
else Omega0: = Arccos ((d / 2-t) / (d / 2)); N: = 10;
asr: = 0; ai: = 0; asr0: = 0; for jjj: = 1 to N do
begin Omegai: = Omega0 / N * jjj;
ai: = sz * sin (Omegai) * cos (tau); //10.03.14
asr0: = asr0 + ai;
end;
154

asr: = asr0 / N; // average value tolschini sreza


// ------------------------------------------------ -------------------------------------------------- ---- ex: = (2 * pi-Omega0) /
Omega0; // otnoshenie taux / taup
taur: = 3 * d * Omega0 / 100 / v; // vremya rabochee, c
// ------------------------------------------------ writeln
(File1, 'Axial tooth pitch hh, mm = ', hh: 4: 1);
writeln (File1, 'tooth length for cylindrical. parts S, mm = ', b1: 4: 1);
writeln (File1, 'Feed per tooth sz = ', sz: 3: 3,' mm / zub ');
writeln (File1, 'Maximum thickness in the direction of horizon amax =.', amax: 3: 3, 'mm'); writeln (File1, 'average
thickness asr = ', asr: 3: 3,' mm ');
writeln (File1, '--------------------------------------'); zp: = 1;
tauz: = 2 * pi / z; // uglovoi shag zub'ev
Px: = 0; M12: = 0; Pxsum: = 0; M12sum: = 0;
Pz: = 0; Rcz: = 0; Pmz: = 0; F2: = 0; Rcy: = 0; Pmy: = 0; P2: = 0; Px12: = 0; P212: = 0; //
------------------------------ strength calculation on the cylindrical part writeln (File1, '1 ------- - first cutting
tooth at maximum slice thickness'); // Form1.Memo1.Lines.Add ( '1 -------- first cutting tooth'); //
-------------------------------- // Calculation of wear rate dtau: = 0.2;

// min
t0: = 0; hz: = hz;
writeln (File1, 'sz, mm / zub =', sz: 4: 3); writeln
(File1, 'n, ob / min =', nn: 4: 1); writeln (File1, 'v, m
/ min =', v: 3: 1); writeln (File1, '
t0 hz Intr Tp td Pz Py Px Teta ');
IF (amax> 0.01) and (BB> r) then while
(hz <= hzmax) do {1:} BEGIN

// ******************************* settlement procedure forces on cylindrical. parts


// calculation of forces, temperatures, properties of OM as a function of Td
Sigma_Cilindr; // 1st tooth on the maximum thickness of the slice
begin t0: = t0 + dtau; dhz: = dtau * Intr; hz: = hz + dhz; // mm
end;
M12: = (Rcz + Pmz + F2) * d / 2000; // Hm
Px: = (Rcy + Pmy + P2) * sin (tet); Px12: = Px; P212: = P2;
writeln (File1, '', t0: 4: 1, '', hz: 2: 4, '', Intr: 4: 6, '', Tpp: 4: 1, '', Td: 4: 1 ' ', (Rcz + Pmz + F2): 4: 1,' ', (Rcy + Pmy + P2) * cos
(tet): 4: 1,' ', (Rcy + Pmy + P2) * sin (tet): 4: 1 ' ', Teta: 4: 1);
Pxsum: = Px; M12sum: = M12; {1:}
END;
writeln (File1, 'wear quantity hz = ', hz: 3: 2,' mm ');
writeln (File1, 'treatment time - resistance t0 =', t0: 3: 1, 'min'); writeln (File1, 'moment of
the first tooth M12 = ', M12: 4: 1,' Hm '); Form1.Memo1.Lines.Add ( 'Power on the Z
axis Pz = (Rcz + Pmz + F2) =
'+ FloatToStrF ((Rcz + Pmz + F2), FFGeneral, 4,6) +' H ');
Form1.Memo1.Lines.Add ( 'Torque M12 =
'+ FloatToStrF (M12, FFGeneral, 4,6) +' Nm ');
// 2nd tooth on the intermediate slice thickness
hz: = hzmax; //
-------------------
if tauz <psi0 then begin psi0: = psi0-tauz;
if (t <d / 2) then tet: = arccos (+ cos (tau) * sin (psi0) /
sqrt (sqr (sin (tau)) + sqr (cos (tau)) * sqr (sin (psi0)))) // mejdu vektorom Cxy i osu Y
else tet: = tau;
155

Omega0: = psi0; N: =
10; asr: = 0; ai: = 0; asr0: = 0; for jjj: = 1 to N do
begin Omegai: = Omega0 / N * jjj;
ai: = sz * sin (Omegai) * cos (tau); asr0: =
asr0 + ai; end; asr: = asr0 / N; writeln (File1, '');

writeln (File1, '2 -------- second cutting tooth in an intermediate slice thickness'); Form1.Memo1.Lines.Add ( '2
------- second cutting tooth in an intermediate slice thickness');

zp: = 2; Px12_2: = 0; P212_2: = 0; p2: = 0;


// ************************* settlement procedure forces on cylindrical. Part 2 of the tooth
// calculation of forces, temperatures, properties of OM as a function of Td
Sigma_Cilindr; // 2nd tooth on proiezhutochnoy slice thickness
M12: = (Rcz + Pmz + F2) * d / 2000; // Hm
Form1.Memo1.Lines.Add ( 'Power on the cylindrical part of the 2nd tooth');
Form1.Memo1.Lines.Add ( 'Power on the Z axis Pz = (Rcz + Pmz + F2) =
'+ FloatToStrF ((Rcz + Pmz + F2), FFGeneral, 4,6) +' H ');
Form1.Memo1.Lines.Add ( 'Power on the Y axis Py = (Rcy + Pmy + P2) cos (tet) =' + FloatToStrF
((Rcy + Pmy + P2) * cos (tet), FFGeneral, 4,6) + 'H');
Form1.Memo1.Lines.Add ( 'Power on axis X Px = (Rcy + Pmy + P2) sin (tet) =' + FloatToStrF ((Rcy
+ Pmy + P2) * sin (tet), FFGeneral, 4,6) + 'H');
Form1.Memo1.Lines.Add ( 'pressure on the cutting edge sigmam =' + FloatToStrF
(sigmam, FFGeneral, 4,6) + 'MPa');
Form1.Memo1.Lines.Add ( 'Torque M12 =
'+ FloatToStrF (M12, FFGeneral, 4,6) +' H.m ');
Form1.Memo1.Lines.Add ( 'cutting temperature Tp =' + FloatToStrF (Tpp, FFGeneral, 4,6) + 'grad');

writeln (File1, 'Maximum thickness of the second tooth amax =', amax: 3: 3, 'mm'); writeln (File1,
'average thickness asr = ', asr: 3: 3,' mm ');
writeln (File1, 'Power on the Z axis on one tooth Pz = (Rcz + Pmz + F2) = ', (Rcz + Pmz + F2): 4: 1'
H ');
writeln (File1, 'Power on the Y axis Py = (Rcy + Pmy + P2) cos (tet) =
', (Rcy + Pmy + P2) * cos (tet): 4: 1,' H ');
writeln (File1, 'Power on X axis along the cutter axis Px = (Rcy + Pmy + P2) sin (tet) =', (Rcy + Pmy + P2) *
sin (tet): 4: 1, 'H');
writeln (File1, 'Power on the rear surface P2 = ', P2: 4: 1,' H ');
writeln (File1, 'pressure on the cutting edge sigmam =', sigmam: 4: 1, 'MPa'); writeln (File1, 'Torque
on the second tooth M12_2 =', M12: 4: 1, 'H.m'); writeln (File1, 'cutting temperature Tp =', Tpp: 4:
1, 'grad'); Px: = (Rcy + Pmy + P2) * sin (tet); Px12_2: = Px; P212_2: = P2; Pxsum: = Pxsum + Px;
M12sum: = M12sum + M12;

end;
writeln (File1, 'cutting teeth zp = ', zp: 2: 1);
writeln (File1, 'Power on the cylindrical portion 1 and 2 th tooth Px =', Pxsum: 4: 1, 'H'); writeln (File1, 'torque on
cylinder parts 1 and 2 th tooth M12 =.', M12sum: 4: 1, 'H.m'); Form1.Memo1.Lines.Add ( '----------- radiused edge
portion 23 ---------'); Form1.Memo1.Lines.Add ( 'ei, grad
sigmai, MPa ai, mm bi, mm ');
writeln (File1, ' ');
writeln (File1, '1.2) ------ radiused edge portion 23');
156

if (r> 0) then BEGIN //


(Nachalo)
AC: = ro * ((pi / 2-abs (gk)) + alfa); AB: =
ro * (pi / 2-abs (gk)); writeln (File1, 'ei
Ri Gami Beti sigmai ai bi Pzi Ni Pxi Pyi
Tp, oC Td P2i ');
if BB> = r then e: = e
else e: = arccos ((r-BB) / r);
bi: = r * e / k; aai: = 0; M23: = 0; Pzi: = 0; Rczi: = 0; Pmzi: = 0; F2i: = 0; zpi: = 0; Pyi: = 0; Pxi: = 0;
Px23: = 0; Py23: = 0; Pz23: = 0; Ni: = 0; P223: = 0; p2i: = 0; // loop through the points on the radiused
edge portion for i: = 1 to k do {2} BEgin de: = e / k;
// sum of all points on the radius
part of the edge
ei: = e * (1-1 / k * i) + de / 2; Ri: = d /
2-r * (1-sin (ei)); // current range
// if the radius is greater than the depth, continue to the end of the cycle if (Ri> (d / 2-t))
then {1} begin // depth less than the radius
if (t <d / 2) then begin psi0i: = ArcCos ((d / 2-t) / Ri);
amaxi: = sz * (sin (tau) * cos (ei) + cos (tau) * sin (ei) * sin (psi0i)); zpi: = psi0i / 2 /
pi * z; end else {t> d / 2}

begin
psi0i: = pi / 2;
amaxi: = sz * (sin (tau) * cos (ei) + cos (tau) * sin (ei) * sin (psi0i)); zpi: = psi0i / 2 /
pi * z; end; aai: = amaxi;

if zpi <1 then zpi: = 1 else zpi: = zpi; a: = aai;


N: = 10;
gamsr: = 0; // mean value along the edge
if (a> h) then da: = (ah) / N else da: = 0;
for j: = 1 to N do begin if da> 0 then
begin ai: =
h + j * da;
if ai <a0 then gami: = arcsin ((ai-ro) / ro) else gami:
= gam0; gamsr: = gamsr + gami;

end;
end; gam: = gamsr / N;

if (aai> 0.01) then Begin gi: = gam; alfi: = alfa;


zpi: = 1; Sigma_Radius (ei, bi, gi, alfi, aai);
// 1st tooth on the maximum thickness of the slice
Pzi: = (Rczi + Pmzi + F2i); Ni: = (Rcyi + Pmyi + P2i); Pxi: = Ni * cos
(ei); Pyi: = Ni * sin (ei);

M23: = M23 + Pzi * Ri / 1000; // moment, Hm


Form1.Memo1.Lines.Add (FloatToStrF (ei * 180 / pi, FFGeneral, 4,6) + ' '+
FloatToStrF (sigmami, FFGeneral, 4,4) + ' '
+ FloatToStrF (aai, FFGeneral, 4,4) + ' '+
FloatToStrF (bi, FFGeneral, 4,4));
157

writeln (File1, '', ei * 180 / pi: 4: 1, '', Ri: 4: 2 ' ', Gi * 180 / pi: 4: 1,' ', beti * 180 / pi: 4: 1' ', Sigmami: 4: 1'
', Aai: 4: 3,' ', bi: 4: 3' ', Pzi: 4: 2' ', Ni: 3: 1' ', Pxi: 3: 1' ', Pyi: 3: 1' ', Tpp: 4: 1' ', Td: 4: 1'
', P2i: 4: 1,' the first cutting tooth 1- ');
Px23: = Px23 + Pxi; Py23:
= Py23 + Pyi; pz23: =
Pz23 + Pzi; P223: = P223
+ P2i;
End;
// 2nd tooth on proiezhutochnoy Px23_2 slice thickness: = 0;
P223_2: = 0; p2i: = 0;
if tauz <psi0i then {3} BEGIN psi0i: = psi0i-tauz;
aai: = sz * (sin (tau) * cos (ei) + cos (tau) * sin (ei) * sin (psi0i)); a: = aai; N: =
10;
gamsr: = 0; // mean value along the edge
if (a> h) then da: = (ah) / N else da: = 0;
for j: = 1 to N do begin if da> 0 then
begin ai: =
h + j * da;
if ai <a0 then gami: = arcsin ((ai-ro) / ro) else gami:
= gam0; gamsr: = gamsr + gami;

end;
end; gam: = gamsr / N; if
(aai> 0.01) then Begin gi: =
gam; alfi: = alfa; zpi: = 2;

Sigma_Radius (ei, bi, gi, alfi, aai); // 2nd tooth on the intermediate slice thickness
Pzi: = (Rczi + Pmzi + F2i); Ni: = (Rcyi + Pmyi + P2i); Pxi: = Ni * cos
(ei); Pyi: = Ni * sin (ei);

M23: = M23 + Pzi * Ri / 1000 * zpi; // moment, Hm


Form1.Memo1.Lines.Add (FloatToStrF (ei * 180 / pi, FFGeneral, 4,6) + ' '
+ FloatToStrF (aai, FFGeneral, 4,4) + ' '+
FloatToStrF (bi, FFGeneral, 4,4));
writeln (File1, '', ei * 180 / pi: 4: 1, '', Ri: 4: 2 ' ', Gi * 180 / pi: 4: 1,' ', beti * 180 / pi: 4: 1' ', Sigmami: 4: 1'
', Aai: 4: 3,' ', bi: 4: 3' ', Pzi: 4: 2' ', Ni: 3: 1' ', Pxi: 3: 1' ', Pyi: 3: 1' ', Tpp: 4: 1' ', Td: 4: 1'
', P2i: 4: 1,' second cutting tooth 1-- ');
Px23_2: = Px23_2 + Pxi; // total of two teeth
Py23: = Py23 + Pyi; Pz23: =
Pz23 + Pzi; P223_2: = P223_2 +
P2i;
End; {3}
END {1}
end;
{2} ENd; // end loop through all points on the radius of the edge writeln (File1, 'The
number of cutting teeth zpi = ', zpi: 4: 2);
writeln (File1, 'total force component on the radiused edge part:.'); writeln (File1, 'Pz23 =',
Pz23: 4: 1, 'H'); writeln (File1, 'Py23 =', Py23: 4: 1, 'H'); writeln (File1, 'Px23 =', Px23 +
Px23_2: 4: 1, 'H');
158

Form1.Memo1.Lines.Add ( 'Torque on radiused portion M23 =' + FloatToStrF (M23,


FFGeneral, 4,4) + 'Nm');
writeln (File1, 'torque at the radiused portion M23 =', M23: 4: 2, 'H.m'); END; // end

// end tooth
aaj: = 0; amaxj: = 0; M34: = 0; Pzj: = 0; Rczi: = 0; Pmzi: = 0; F2i: = 0; zpj: = 0; z56: = 0; z78: = 0; psi0j: = 0;

Pyj: = 0; Pxj: = 0; Px34: = 0; Py34: = 0; Pz34: = 0; P234: = 0; P2i: = 0; if (tau> 0) then


// end edge works only at an angle of tau
Begin
writeln (File1, ' ');
Form1.Memo1.Lines.Add ( '----------------- The end edge 34 ----------');
Form1.Memo1.Lines.Add ( 'Rj, mm sigmaj, MPa aj, mm bj, mm ');
writeln (File1, 'Rj gamj betj sigmaj aaj bj Pzj Nj Pxj Pyj Tp, oC
Td M P2j '); str: =
Edit20.Text; gam0t: = FormatTranslate (str) * pi / 180; // rad na torce
AC: = ro * ((pi / 2-abs (gk)) + alfa); AB: = ro * (pi / 2-abs (gk));
h: = ro / 3; gk: = - arcsin ((ro-h) / ro); Rj: = d
/ 2-r;
Ri: = Rj / 2; // edge of the middle
if (t <= d / 2) and (t> r) then psi0j: = ArcCos ((d / 2-t) / Rj)
else {t> d / 2}
psi0j: = pi / 2; // Ro maximum slice thickness if t <= r then
psi0j: = 0;
Px34: = 0; Py34: = 0; Pz34: = 0; M34: = 0; amaxj: = 0; P2i: = 0; // net rezaniya na torcevom zube szj: = sz; bj: = Rj / cos
(fi1);

tet: = arccos (+ cos (tau) * sin (psi0j) / sqrt (sqr (sin (tau)) + sqr (cos (tau)) * sqr (sin (psi0j)))); if (tau> fi1) then if t
<(d / 2) then
amaxj: = szj * sqrt (sqr (sin (tau)) + sqr (cos (tau)) * sqr (sin (psi0j))) * sin (tet-fi1)
else amaxj: = szj * sin (tet-fi1); // t> d / 2
if amaxj> 0 then begin aaj: = amaxj; N: = 10;
a: = aaj;
gamsr: = 0;
if a> h then da: = (ah) / N else da: = 0; for i: = 1
to N do begin if da> 0 then
begin ai: =
h + i * da;
if ai <a0 then gami: = arcsin ((ai-ro) / ro) else gami:
= gam0t; gamsr: = gamsr + gami;

end;
end;
gam: = gamsr / N; // take the average value of the front. angle along the edge if (aaj> 0.01) then
Begin zpj: = 1; // 1st tooth on the maximum thickness of the slice
writeln (File1, '1.3 ------- The end edge 34');
gj: = gam; alfj: = alfa;
1 ------------------- // end tooth 34 Sigma_Torec
(0, bj, gj, alfj, aaj); // ------------------------

Pzj: = (Rczi + Pmzi + F2i); Nj: = (Rcyi + Pmyi + P2i); Pxj: = Nj *


cos (fi1);
159

Pyj: = Nj * sin (fi1); M34: = M34 + Pzj * Rj /


2/1000; // moment, Hm
Form1.Memo1.Lines.Add (FloatToStrF (Rj / 2, FFGeneral, 4,6) + ' '
+ FloatToStrF (sigmami, FFGeneral, 4,4) + ' '+
FloatToStrF (aaj, FFGeneral, 4,3) + ' '+ FloatToStrF (bj, FFGeneral, 4,3));
writeln (File1, 'z34 - one');
writeln (File1, '', Rj / 2: 2: 1, '', gj * 180 / pi: 4: 2, '', beti * 180 / pi: 4: 1, '', sigmami: 4: 1, ' ', Aaj: 4: 3' '
. bj: 4: 3 ' ', Pzj: 4: 2,' ', Nj: 3: 1' ', Pxj: 3: 1' ', Pyj: 3: 1' ', Tpp: 4: 1' ', Td: 4: 1,' ', M34: 2: 2'
', P2i: 4: 1);
end;
Px34: = Px34 + Pxj; Py34:
= Py34 + Pyj; pz34: =
Pz34 + Pzj; P234: = P234
+ P2i;
End; if (tauz
<psi0j) then // this condition can be satisfied for the number of teeth z> 4
BEGIN
writeln (File1, ' '); // 2nd tooth on the end
psi0j: = psi0j-tauz; zpj: = 2;
tet: = arccos (+ cos (tau) * sin (psi0j) / sqrt (sqr (sin (tau)) + sqr (cos (tau)) * sqr (sin (psi0j)))); Rj: = Kzub * d / 2-r;
// dlina kromki
bj: = Rj / cos (fi1); // Shirina Sreza
if (tau> fi1) then amaxj: = szj * sqrt (sqr (sin (tau)) + sqr (cos (tau)) * sqr (sin (psi0j))) * sin (tet-fi1)
else amaxj: = szj * sin (tet-fi1); if
amaxj> 0 then begin aaj: = amaxj; N: = 10;
a: = aaj;
gamsr: = 0;
if a> h then da: = (ah) / N else da: = 0; for i: = 1
to N do begin if da> 0 then
begin ai: =
h + i * da;
if ai <a0 then gami: = arcsin ((ai-ro) / ro) else gami:
= gam0t; gamsr: = gamsr + gami;

end;
end; gam: = gamsr / N;
// take the average value of the front. angle along the edge
// ------------------------------------------------ ------ if (aaj> 0.01)
then Begin gj: = gam; alfj: = alfa;
// ------------------ 2nd tooth on the end - reducing the length of the tooth on the end face of the coefficients. Kzub

Sigma_Torec (0, bj, gj, alfj, aaj); // -------------------------------------


Pzj: = (Rczi + Pmzi + F2i); Nj: = (Rcyi + Pmyi + P2i); Pxj: = Nj *
cos (fi1); Pyj: = Nj * sin (fi1);

M34: = M34 + Pzj * (d / 2-r-Rj / 2) / 1000; // moment, Hm


Form1.Memo1.Lines.Add (FloatToStrF (Rj, FFGeneral, 4,6) + ' '
+ FloatToStrF (sigmami, FFGeneral, 4,4) + ' '+
FloatToStrF (aaj, FFGeneral, 4,4) + ' '+ FloatToStrF (bj, FFGeneral, 4,4));
writeln (File1, 'z34 - two');
160

writeln (File1, '', Rj: 2: 1, '', gj * 180 / pi: 4: 2, '', beti * 180 / pi: 4: 1, '', sigmami: 4: 1 ' ', Aaj: 4: 3' ', Bj: 4: 3'
', Pzj: 4: 2,' ', Nj: 3: 1' ', Pxj: 3: 1' ', Pyj: 3: 1' ', Tpp: 4: 1' ', Td: 4: 1,' ', M34: 2: 2,' ', P2i: 4: 1);
end;
Px34: = Px34 + Pxj; // total force of two teeth
Py34: = Py34 + Pyj;
Pz34: = Pz34 + Pzj;
End;
END;
// reverse the teeth at the end of 56 Z = 2 z56: = 0;
z78: = 0; P256: = 0; P2i: = 0;
Form1.Memo1.Lines.Add ( '------- ---------- The end edge 56');
Form1.Memo1.Lines.Add ( 'Rj, mm sigmaj, MPa aj, mm bj, mm ');
// z = 2 - the number of cutter teeth If (t> = (d / 2)) and
(z = 2) and (tau> 0) then {1} BEGIN

writeln (File1, ' ');


tet0: = pi / 2; Rj: = d
/ 2-r; z56: = 1; // z = 2 when the second tooth is the same as the first
bj: = Rj / cos (fi1);
tet: = arccos (cos (tau) * sin (tet0) / sqrt (sqr (sin (tau)) + sqr (cos (tau)) * sqr (sin (tet0)))); aaj: = szj * sqrt (sqr
(sin (tau)) + sqr (cos (tau)) * sqr (sin (tet0))) * sin (tet + fi1); N: = 10;
a: = aaj; gamsr: = 0;
if a> h then da: = (ah) / N else da: = 0; for i: = 1
to N do begin if da> 0 then
begin ai: = h + i *
da;
if ai <a0 then gami: = arcsin ((ai-ro) / ro)
else gami: = gam0t;
gamsr: = gamsr + gami; end; end;

gam: = gamsr / N;
if (aaj> 0.01) then Begin gj: = gam; alfj: = alfa;
// ---- return tooth 56 on the end
Sigma_Torec (0, bj, gj, alfj, aaj);
Pzj: = (Rczi + Pmzi + F2i); Nj: = (Rcyi + Pmyi + P2i); Pxj: = Nj * cos
(fi1); Pyj: = Nj * sin (fi1); M56: = Pzj * Rj / 2/1000;

// moment, Hm

writeln (File1, '--------- Reverse teeth on the end 56'); // Form1.Memo1.Lines.Add (


'--------- -------- The end edge 56'); Form1.Memo1.Lines.Add (FloatToStrF (Rj / 2,
FFGeneral, 4,6) + ' '
+ FloatToStrF (sigmami, FFGeneral, 4,3) + ' '+
FloatToStrF (aaj, FFGeneral, 4,3) + ' '+ FloatToStrF (bj, FFGeneral, 4,3));
writeln (File1, 'z56'); writeln (File1, '',
Rj / 2: 2: 1 ' ', Gj * 180 / pi: 4: 2,' ', beti * 180 / pi: 4: 1,' ', sigmami: 4: 1' ', Aaj: 4: 3' '
. bj: 4: 3 ' ', Pzj: 4: 2' ', Nj: 3: 1' ', Pxj: 3: 1' ', Pyj: 3: 1' ', Tpp: 4: 1' ', Td: 4: 1,' ', M56: 2: 2'
', P2i: 4: 1);
Px56: = Pxj; // total of all forces on the end zubuv
Py56: = Pyj;
Pz56: = Pzj;
161

P256: = P2i;
End;
{1} END;
If (t <(d / 2)) and (z = 2) and (tau> 0) then {1}
BEGIN writeln (File1, ' ');
psi0: = arccos ((d / 2-t) / (d / 2)); tet0: =
psi0; Rj: = d / 2-r;
z56: = 1;
bj: = Rj / cos (fi1);
tet: = arccos (cos (tau) * sin (tet0) / sqrt (sqr (sin (tau)) + sqr (cos (tau)) * sqr (sin (tet0)))); aaj: = szj * sqrt (sqr
(sin (tau)) + sqr (cos (tau)) * sqr (sin (tet0))) * sin (tet + fi1); N: = 10;
a: = aaj; gamsr: = 0;
if a> h then da: = (ah) / N else da: = 0; for i: = 1
to N do begin if da> 0 then
begin ai: = h + i *
da;
if ai <a0 then gami: = arcsin ((ai-ro) / ro)
else gami: = gam0t;
gamsr: = gamsr + gami; end; end;

gam: = gamsr / N;
if (aaj> 0.01) then Begin gj: = gam; alfj: = alfa;
Sigma_Torec (0, bj, gj, alfj, aaj);
Pzj: = (Rczi + Pmzi + F2i); Nj: = (Rcyi + Pmyi + P2i); Pxj: = Nj * cos
(fi1); Pyj: = Nj * sin (fi1); M56: = Pzj * Rj / 2/1000;

// moment, Hm
writeln (File1, '--------- Reverse teeth on the end 56');
Form1.Memo1.Lines.Add ( '--------- Reverse teeth on the end face 56 -----------');
Form1.Memo1.Lines.Add (FloatToStrF (Rj / 2, FFGeneral, 4,6) + ' '
+ FloatToStrF (sigmami, FFGeneral, 4,4) + ' '+
FloatToStrF (aaj, FFGeneral, 4,4) + ' '+ FloatToStrF (bj, FFGeneral, 4,4));
writeln (File1, 'z56'); writeln (File1, '',
Rj / 2: 2: 1 ' ', Gj * 180 / pi: 4: 2,' ', beti * 180 / pi: 4: 1,' ', sigmami: 4: 1' ', Aaj: 4: 3' '
. bj: 4: 3 ' ', Pzj: 4: 2' ', Nj: 3: 1' ', Pxj: 3: 1' ', Pyj: 3: 1' ', Tpp: 4: 1' ', Td: 4: 1,' ', M56: 2: 2'
', P2i: 4: 1);
Px56: = Pxj; // total of all forces on the end zubuv
Py56: = Pyj;
Pz56: = Pzj;
P256: = P2i;
End;
{1} END;
If (t> = (d / 2)) and (z = 3) and (tau> 0) then {1}
BEGIN writeln (File1, ' ');
z78: = 0; z56: = 1; tet0: = abs (2 * pi / z-pi / 2); Rj: = d / 2
* Kzub-r; bj: = Rj / cos (fi1);
tet: = arccos (cos (tau) * sin (tet0) / sqrt (sqr (sin (tau)) + sqr (cos (tau)) * sqr (sin (tet0)))); aaj: = szj * sqrt (sqr
(sin (tau)) + sqr (cos (tau)) * sqr (sin (tet0))) * sin (tet + fi1); N: = 10;
a: = aaj; gamsr: = 0;
if a> h then da: = (ah) / N else da: = 0; for i: = 1
to N do begin if da> 0 then
162

begin ai: = h + i *
da;
if ai <a0 then gami: = arcsin ((ai-ro) / ro)
else gami: = gam0t;
gamsr: = gamsr + gami; end; end;

gam: = gamsr / N;
if (aaj> 0.01) then Begin gj: = gam; alfj: = alfa;
// ---- return tooth 56 on the end
Sigma_Torec (0, bj, gj, alfj, aaj);
Pzj: = (Rczi + Pmzi + F2i); Nj: = (Rcyi + Pmyi + P2i); Pxj: = Nj * cos
(fi1); Pyj: = Nj * sin (fi1); M56: = Pzj * (d / 2-r-Rj / 2) / 1000;

// moment, Hm
writeln (File1, '--------- Reverse teeth on the end face 56 -----------------'); Form1.Memo1.Lines.Add ( '----------- Return
the teeth at the end of 56 ------------------------- '); Form1.Memo1.Lines.Add (FloatToStrF (Rj, FFGeneral, 4,6) + '
'
+ FloatToStrF (sigmami, FFGeneral, 4,4) + ' '+
FloatToStrF (aaj, FFGeneral, 4,4) + ' '+ FloatToStrF (bj, FFGeneral, 4,4));
writeln (File1, 'z56'); writeln
(File1, '', Rj: 2: 1 ' ', Gj * 180 / pi: 4: 2,' ', beti * 180 / pi: 4: 1,' ', sigmami: 4: 1' ', Aaj: 4: 3' '
. bj: 4: 3 ' ', Pzj: 4: 2' ', Nj: 3: 1' ', Pxj: 3: 1' ', Pyj: 3: 1' ', Tpp: 4: 1' ', Td: 4: 1,' ', M56: 2: 2'
', P2i: 4: 1);

Px56: = Pxj; // total of all forces on the end zubuv


Py56: = Pyj;
pz56: = Pzj;
P256: = P2i;
End;
// zub 78
P278: = 0; P2i: = 0; tet0: = abs
(2 * pi / z-pi / 2); Rj: = d / 2 *
Kzub-r; z78: = 1; bj: = Rj / cos (fi1);
tet: = arccos (cos (tau) * sin (tet0) / sqrt (sqr (sin (tau)) + sqr (cos (tau)) * sqr (sin (tet0)))); aaj: = szj * sqrt (sqr
(sin (tau)) + sqr (cos (tau)) * sqr (sin (tet0))) * sin (tet + fi1); N: = 10;
a: = aaj; gamsr: = 0;
if a> h then da: = (ah) / N else da: = 0; for i: = 1
to N do begin if da> 0 then
begin ai: = h + i *
da;
if ai <a0 then gami: = arcsin ((ai-ro) / ro)
else gami: = gam0t;
gamsr: = gamsr + gami; end; end;

gam: = gamsr / N;
if (aaj> 0.01) then Begin gj: = gam; alfj: = alfa;
// ---- return tooth 56 on the end
Sigma_Torec (0, bj, gj, alfj, aaj);
Pzj: = (Rczi + Pmzi + F2i); Nj: = (Rcyi + Pmyi + P2i); Pxj: = Nj *
cos (fi1);
163

Pyj: = Nj * sin (fi1); M78: = Pzj * (d / 2-r-Rj /


2) / 1000; // moment, Hm
writeln (File1, '---------- Inverse teeth on the end ---------------------- 78'); Form1.Memo1.Lines.Add (
'---------- Back at the end of the teeth 78 ----------------'); Form1.Memo1.Lines.Add (FloatToStrF (Rj,
FFGeneral, 4,6) + ' '
+ FloatToStrF (sigmami, FFGeneral, 4,4) + ' '+
FloatToStrF (aaj, FFGeneral, 4,4) + ' '+ FloatToStrF (bj, FFGeneral, 4,4));
writeln (File1, 'z78'); writeln
(File1, '', Rj: 2: 1 ' ', Gj * 180 / pi: 4: 2,' ', beti * 180 / pi: 4: 1,' ', sigmami: 4: 1' ', Aaj: 4: 3' '
. bj: 4: 3 ' ', Pzj: 4: 2' ', Nj: 3: 1' ', Pxj: 3: 1' ', Pyj: 3: 1' ', Tpp: 4: 1' ', Td: 4: 1,' ', M78: 2: 2'
', P2i: 4: 1);
Px78: = Pxj; // total of all forces on the end zubuv
Py78: = Pyj;
Pz78: = Pzj;
P278: = P2i;
End;
{1} END;
If (t <(d / 2)) and (t> r) and (z = 3) and (tau> 0) then {1}
BEGIN // zub 56
writeln (File1, ' ');
psi0: = arccos ((d / 2-t) / (d / 2)); tet0: = abs (2 *
pi / z + psi0-pi); Rj: = d / 2 * Kzub-r; bj: = Rj / cos
(fi1); z56: = 1;
z78: = 0;
tet: = arccos (cos (tau) * sin (tet0) / sqrt (sqr (sin (tau)) + sqr (cos (tau)) * sqr (sin (tet0)))); aaj: = szj * sqrt (sqr
(sin (tau)) + sqr (cos (tau)) * sqr (sin (tet0))) * sin (tet + fi1); N: = 10;
a: = aaj; gamsr: = 0;
if a> h then da: = (ah) / N else da: = 0; for i: = 1
to N do begin if da> 0 then
begin ai: = h + i *
da;
if ai <a0 then gami: = arcsin ((ai-ro) / ro)
else gami: = gam0t;
gamsr: = gamsr + gami; end; end;

gam: = gamsr / N;
if (aaj> 0.01) then Begin gj: = gam; alfj: = alfa;
// ---- return tooth 56 on the end
Sigma_Torec (0, bj, gj, alfj, aaj);
Pzj: = (Rczi + Pmzi + F2i); Nj: = (Rcyi + Pmyi + P2i); Pxj: = Nj * cos
(fi1); Pyj: = Nj * sin (fi1); M56: = Pzj * (d / 2-r-Rj / 2) / 1000;

// moment, Hm
writeln (File1, '----------- Inverse teeth on the end ---------------------- 56'); Form1.Memo1.Lines.Add (
'----------- Inverse teeth on the end ------------------- 56'); Form1.Memo1.Lines.Add (FloatToStrF (Rj,
FFGeneral, 4,6) + ' '
+ FloatToStrF (sigmami, FFGeneral, 4,4) + ' '+
FloatToStrF (aaj, FFGeneral, 4,4) + ' '+ FloatToStrF (bj, FFGeneral, 4,4));
writeln (File1, 'z56');
164

writeln (File1, '', Rj: 2: 1 ' ', Gj * 180 / pi: 4: 2,' ', beti * 180 / pi: 4: 1,' ', sigmami: 4: 1' ', Aaj: 4: 3' '
. bj: 4: 3 ' ', Pzj: 4: 2' ', Nj: 3: 1' ', Pxj: 3: 1' ', Pyj: 3: 1' ', Tpp: 4: 1' ', Td: 4: 1,' ', M56: 2: 2'
', P2i: 4: 1);
Px56: = Pxj; // total of all forces on the end zubuv
Py56: = Pyj;
Pz56: = Pzj;
P256: = P2i;
End;
{1} END;
If (t <(d / 2)) and (t> r) and (z = 3) and (tau> 0) then {1}
BEGIN // zub 78
writeln (File1, ' ');
psi0: = arccos ((d / 2-t) / (d / 2)); tet0: = abs (2 *
pi / z + psi0-pi); Rj: = d / 2 * Kzub-r; bj: = Rj / cos
(fi1); z56: = 0;
z78: = 1;
tet: = arccos (cos (tau) * sin (tet0) / sqrt (sqr (sin (tau)) + sqr (cos (tau)) * sqr (sin (tet0)))); aaj: = szj * sqrt (sqr
(sin (tau)) + sqr (cos (tau)) * sqr (sin (tet0))) * sin (tet + fi1); N: = 10;
a: = aaj; gamsr: = 0;
if a> h then da: = (ah) / N else da: = 0; for i: = 1
to N do begin if da> 0 then
begin ai: = h + i *
da;
if ai <a0 then gami: = arcsin ((ai-ro) / ro)
else gami: = gam0t;
gamsr: = gamsr + gami; end; end;

gam: = gamsr / N;
if (aaj> 0.01) then Begin gj: = gam; alfj: = alfa;
// ---- return tooth 78 on the end
Sigma_Torec (0, bj, gj, alfj, aaj);
Pzj: = (Rczi + Pmzi + F2i); Nj: = (Rcyi + Pmyi + P2i); Pxj: = Nj * cos
(fi1); Pyj: = Nj * sin (fi1); M78: = Pzj * (d / 2-r-Rj / 2) / 1000;

// moment, Hm
writeln (File1, '----------- Inverse teeth on the end face 78 ---------------------');
Form1.Memo1.Lines.Add ( '----------- Return the teeth at the end of 78');
Form1.Memo1.Lines.Add (FloatToStrF (Rj, FFGeneral, 4,6) + ' '
+ FloatToStrF (sigmami, FFGeneral, 4,4) + ' '+
FloatToStrF (aaj, FFGeneral, 4,4) + ' '+ FloatToStrF (bj, FFGeneral, 4,4));
writeln (File1, 'z78'); writeln
(File1, '', Rj: 2: 1 ' ', Gj * 180 / pi: 4: 2,' ', beti * 180 / pi: 4: 1,' ', sigmami: 4: 1' ', Aaj: 4: 3' '
. bj: 4: 3 ' ', Pzj: 4: 2' ', Nj: 3: 1' ', Pxj: 3: 1' ', Pyj: 3: 1' ', Tpp: 4: 1' ', Td: 4: 1,' ', M78: 2: 2'
', P2i: 4: 1);
Px78: = Pxj; // total of all forces on the end zubuv
Py78: = Pyj;
pz78: = Pzj;
P278: = P2i;
End;
{1} END; End;
// (tau> 0)
165

writeln (File1, 'The number of cutting teeth at the end of 34 z34 = ', zpj: 2);
writeln (File1, 'inverse number of teeth on the end of 56 z56 = ', z56: 2);
writeln (File1, 'inverse number of teeth on the end of 78 z78 = ', z78: 2);
writeln (File1, 'total force component on the end edges:.'); writeln (File1, 'Pz34 + 56 + 78
=', Pz34 + Pz56 + Pz78: 4: 1, 'H'); writeln (File1, 'Py34 + 56 + 78 =', Py34 + Py56 +
Py78: 4: 1, 'H'); writeln (File1, 'Px34 + 56 + 78 =', Px34 + Px56 + Px78: 4: 1, 'H');

writeln (File1, 'torque on the end edges M34 + 56 + 78 =', M34 + M56 + M78: 4: 2 '
H.m ');
Form1.Memo1.Lines.Add ( '------- Total moment on the end teeth ------'); Form1.Memo1.Lines.Add ( 'M34 + 56 + 78
=' + FloatToStrF (M34 + M56 + M78, FFGeneral, 4,6) + 'Nm');

Pxsum: = Px12 + Px12_2 + Px23 + Px23_2 + Px34 + Px56 + Px78; writeln


(File1, '---------------');
writeln (File1, 'Summarnaya_sila_Px =', Pxsum: 4: 1, 'H');
Form1.Memo1.Lines.Add ( '----------------------');
Form1.Memo1.Lines.Add ( 'total force Px =' + FloatToStrF (Pxsum, FFGeneral, 4,6) + 'H'); writeln (File1,
'Krutyaschiy_moment_summarnyy_M =', M12sum + M23 + M34 + M56 + M78: 4: 2, 'Nm');

Form1.Memo1.Lines.Add ( 'total moment M =' + FloatToStrF (M12sum + M23 + M34


+ M56 + M78, FFGeneral, 3,1) + 'Nm');
writeln (File1, 'Moschnost_summarnaya_N =', (M12sum + M23 + M34 + M56 + M78) * nn / 9554: 4: 2, 'kWt');

Form1.Memo1.Lines.Add ( 'N = total power


'+ FloatToStrF ((M12sum + M23 + M34 + M56 + M78) * nn / 9554, FFGeneral, 3,1) +' kW ');
Form1.Memo1.Lines.Add ( '---------------------------------'); writeln (File1,
'--------------------------------------'); writeln (File1, '
');
writeln (File1, 'n sz sm B t Q, cm3 / min tau ');
writeln (File1, nn: 3: 1 ' ', Sz: 3: 3' ', Sm: 3: 1,' ', BB: 3: 1' ', T: 3: 1' ', Sm * BB * t / 1000: 5: 1,'
', Tau * 180 / pi: 3: 1);
writeln (File1, 'M12sum =', M12sum: 3: 2); writeln (File1, 'M23 =', M23: 3: 1);
writeln (File1, 'M34 =', M34: 3: 1); writeln (File1, 'M56 =', M56: 3: 1);
writeln (File1, 'M78 =', M78: 3: 1); writeln (File1, 'Msum =
M12sum + M23 + M34 + M56 + M78: 3: 1);
writeln (File1, 'Nsum =', (M12sum + M23 + M34 + M56 + M78) * nn / 9554: 3: 1); writeln (File1,
'Px12 =', Px12: 3: 1); writeln (File1, 'Px12_2 =', Px12_2: 3: 1);
writeln (File1, 'Px23 =', Px23: 3: 1); writeln (File1, 'Px23_2 =', Px23_2: 3: 1);
writeln (File1, 'Px34 =', Px34: 3: 1); writeln (File1, 'Px56 =', Px56: 3: 1);
writeln (File1, 'Px78 =', Px78: 3: 1); writeln (File1, 'Pxsum =', Pxsum: 3: 1);
writeln (File1, ' '); writeln (File1, 'P212 =', P212: 3: 1);
writeln (File1, 'P212_2 =', P212_2: 3: 1); writeln (File1, 'P223 =', P223: 3: 1);
writeln (File1, 'P223_2 =', P223_2: 3: 1); writeln (File1, 'P234 =', P234: 3: 1);
writeln (File1, 'P256 =', P256: 3: 1); writeln (File1, 'P278 =', P278: 3: 1);
writeln (File1, ' '); writeln (File1, 'hz =', hz: 3: 2, 'mm');
Form1.Memo1.Lines.Add ( 'normal force on the edge 23 P223 =' + FloatToStrF
(P223, FFGeneral, 4,6) + 'H');
Form1.Memo1.Lines.Add ( 'normal force on the edge 34 P234 =' + FloatToStrF
(P234, FFGeneral, 4,6) + 'H');
Form1.Memo1.Lines.Add ( 'normal force on the edge 56 P256 =' + FloatToStrF
(P256, FFGeneral, 4,6) + 'H');
166

Form1.Memo1.Lines.Add ( 'normal force on the edge 78 P278 =' + FloatToStrF


(P278, FFGeneral, 4,6) + 'H');
Form1.Memo1.Lines.Add ( '------------ The total normal force at the end ----------------');

Form1.Memo1.Lines.Add ( 'P = (P223 + P234 + P256 + P278), H =


'+ FloatToStrF (P223 + P223_2 + P234 + P256 + P278, FFGeneral, 4,2) +' H ');
end;
closeFile (File1); end;
// Calculation // End of calculation
// -------------------------------------------- procedure
TForm1.ListBox1Click (Sender: TObject); begin

with ListBox1 do Edit18.Text: = Items [ItemIndex]; end;

procedure TForm1.ListBox2Click (Sender: TObject); begin

with ListBox2 do Edit19.Text: = Items [ItemIndex]; end;

procedure TForm1.Button4Click (Sender: TObject); // help


begin
WinExec ( 'hh.exe help.chm', SW_RESTORE); end;

procedure TForm1.Button2Click (Sender: TObject); // exit from Program


begin
Form1.Close;
end; end.
167
168
169
170

COMMENT

scientific adviser Ph.D., assistant professor S. Gross thesis on Zaitsev AM


"Development of ways to increase the efficiency of technological preparation of
production of parts and raketnokosmicheskoy technology nodes", presented for the
degree of candidate of technical sciences, specialty 05.02.07 - Technology and
equipment for mechanical and physical-technical processing and 05.02.08 -

Mechanical engineering technology

On a modern perspective articles raketnokosmicheskoy technology (RCT) should major


scientific and technical challenge to reduce total labor costs and manufacturing deadlines.
Analysis shows that one of the solutions to this problem can be more efficient technological
production preparation (CCI) through the introduction of CAD and PDM-systems electronic
approval process documentation, use of additive technology to create technological equipment,
process optimization, especially in the processing the unique technical requirements of the
components of advanced structural materials, optimization strategies, modes and processing
conditions.

The thesis is Zaitsev AM It aimed at improving the efficiency of CCI parts and assemblies,
primarily advanced rocket and space technology. Considering that in the short and medium term,
planned production of a number of promising new products for space purposes, subject, purpose
and objectives of the thesis are relevant.

This thesis Zaitsev AM New results on CCI complex technical object - the base housing
part with new spacecraft wafer shell structure, including the selection and sequence of processing
strategies, the optimization modes and conditions is guaranteed ensuring the absence of
deformations and the bottom wall of pockets. Conducted research and obtained new scientific
results on machinability high-strength aluminum alloys, which will be for a long period of basic
construction materials to create rocket and space systems. The results of research confirmed
during production testing and implemented in different parts of the CCI procedures and CT units at
JSC "ZEM" RKK "Energy". The results of the studies increased efficiency news: The timing of the
cut by 50%

reduced labor intensity training


Typical beam production piping 36 standard hours and others.
171

The main provisions of the results and conclusions of the study Zaitsev AM reported on 5
national and international scientific conferences, scientific seminars of the department
"Instrumental Techniques and Technologies" MSTU. NE Bauman (2010-2016 GG). The main
content and the results are reflected in the thesis of printed papers 11 and received RF patent.

Zaitsev AM He graduated from the MSTU. NE Bauman MSTU correspondence


postgraduate study, worked at CJSC "ZEM" RKK "Energy" as the deputy chief of the design
department. It maintains close contact with the department in its scientific, methodical and
educational work. He supervises the practice of students, according to its scientific and
engineering experience to the young company's employees, many of whom are graduates of the
Moscow State Technical University. Has proved a qualified engineer and researcher, puts yourself
and solve scientific and technical problems, selects the methods and significant research facilities.

All research results presented in the thesis, obtained personally Zaitsev AM or direct its
participation.

Qualification level Zaitsev AM thesis work and are broadly in line with the requirements.

Zaitsev Aleksei Mikhailovich deserves the award of a scientific degree of candidate of


technical sciences, specialty 05.02.07 - Technology and equipment for mechanical and
physical-technical processing and 05.02.08 - Technology of mechanical engineering.

Scientific adviser,

Ph.D., Associate Professor, Department of

instrumental techniques and technologies

MSTU. NE Bauman SV Rude

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