Operation in aggressive environmental conditions and the interaction of friction pairs impose increased demands on modern parts used in aircraft engine manufacturing and electrical power engineering. Often, working in such conditions leads to the premature failure of parts and equipment, as well as energy loss due to friction and wear processes. Advanced technologies for surface modification and coating deposition by various methods can enhance the performance characteristics of such parts. The technology of laser cladding for wear-resistant coatings, combined with preliminary surface modification, allows the creation of a protective layer on the surface and strengthens it. This paper provides an overview of modern methods for surface modification and deposition of protective coatings using various physical techniques, highlighting their advantages and disadvantages. The most promising method is the laser cladding of wear-resistant coatings with preliminary surface modification. An algorithm for the laser cladding process has been developed for this technology. The paper proposes the use of a new wear-resistant coating made from powder materials based on chromium and molybdenum carbides. The influence of the mixture composition on the properties of the synthesized coating has been determined. Adhesion strength and coating thickness have been evaluated.
Laser Powder Bed Fusion (LPBF) technologies are now being widely adopted across the global industrial landscape. New LPBF systems with multiple lasers and an expanded work area are entering the market, thereby enhancing both the production speed and the maximum size of 3D parts that can be produced. The aim was to investigate the aspects of upscaling LPBF processing parameters on the characteristic formation of stable single tracks, which are the primary building blocks for this technology. A number of LPBF systems were employed in this study, each operating independently and utilizing distinct parameter regimes, to produce the single tracks on a solid substrate deposited with a thin powder layer. The results demonstrated that the geometrical characteristics of single tracks are predominantly influenced by laser power and scanning speed when scanning a thin powder layer. The results also indicate that higher laser power and spot size can be used to produce stable tracks with increasing linear energy input. However, there are a number of nuances to be considered in increasing the performance.
Research of literature dedicated to neural networks and artificial intelligence was made. The topicality of the research in this area was proven. Neural network models most using in computer vision were chosen. The possibility of using a method to detect defects during the process of direct metal deposition based on neural network application was proven. Three neural network models based on U-Net, ResUNet and VGG-16 architectures were trained. The best of three models was chosen. Goals for future researches were set.
Due to high functional properties such as resistance to mechanical, thermal and other physical and chemical impacts, metal matrix composites (MMCs) are widely used in high-tech industries for instance aerospace, automotive, medical, chemical, etc. Modern additive technologies that produce 3D products from metal powders using lasers are unique in terms of the possibility of obtaining new materials and complex parts with the required functional properties in one manufacturing cycle. Laser Powder Bed Fusion (L-PBF) technology makes it possible to greatly facilitate and accelerate the production of such products directly from their CAD (computer-aided design) models. The fundamentals of L-PBF technology provide a significant advantage both in the development of new materials and the manufacture of products from them. However, direct formation (in situ) and application of MMCs in the L-PBF process is constrained by insufficient elaboration of the fundamentals of the formation of these materials during laser processing and incomplete knowledge of the influence of the properties and nature of the initial materials and technological parameters of L-PBF on the final properties of MMCs. The investigation of the processes of forming metal matrix composites by laser-powder bed fusion is driven by the need to ensure stable and confident properties of L-PBF MMCs materials and parts regardless of the equipment used. In this research, the fundamentals of the L-PBF process during in-situ manufacturing of MMCs from dissimilar powders having different melting points and granulomorphometric properties are considered. Preliminary numerical simulations of thermal fields for different parameters of the L-PBF process on the powder mixture have been carried out.
The geometric parameters of sharpening the rake surface are very important for the efficient use of the drill. Therefore, it is important to know the correct sharpening angle of the drill in the radial direction. This is especially important at the stage of regrinding the drill, due to the incorrect installation of the drill into the fixture. In this paper, a new image processing algorithm is proposed that allows you to set indicators and factors that determine the correct choice of the angular position of the drill after regrinding. This algorithm can be of great industrial use due to the simplicity of implementation and minimization of the necessary equipment for setting up the measuring station. The presented model has an important application value and differs from the existing ones in that it can be applied for regrinding of drills with curvilinear cutting edges. This advantage is achieved by using a simpler construction of the drill’s flank surfaces. The proposed design ensures a rational distribution of the clearance angle value along the cutting part regardless of the original shape of the flank surface before the regrinding. Taking into account the limitations of the image processing algorithm and the theoretical model of the cutting part of a tri-flute drill, a rational ratio of the rake and clearance angles obtained by simulating the edge movement in cutting process. This approach allows a radical revision of the traditional recommendations for regrinding process of tri-flute drills. This is becomes possible to solve problems associated with regrinding drills with involute and multi-level flat flank surface. However, the validity of our work still needs to be carefully checked.
The surface grinding of the critical parts is the most important operation, which largely determines the product surface properties and its quality. In the context of automated production, efficient monitoring of this operation is a critically important task. In this work, we propose a new approach to monitoring of grinding: to simulate the processes of generating vibro-acoustic signals during grinding, to divide the working grains of the grinding wheel into sharp grains and low cutting ability ones. This division allows qualitatively predicting changes in the nature of vibro-acoustic signals accompanying grinding in different operational conditions, such as dry grinding and grinding with coolants, and the wear of the grinding wheel. The conclusions obtained based on the phenomenological modeling are confirmed by experimental studies showing that the vibration signal parameters adequately reflect the current state of the technological process and the wear of the grinding wheel. In this work, a new indicator for monitoring the grinding operation of products with high requirements to the quality of the machined surface was identified and evaluated. The proposed approach is shown to yield a more informative diagnostic indicator for finishing process compared to measurements of cutting forces, which are insufficiently efficient in the case of finishing operations with minimum allowance. The indicator was found to be efficient in the case of grinding of surfaces with roughness smaller than 0.4 μmm. The relevance of this indicator has been evaluated and proven in rigid grinding wheel-part-reference system, the use of which minimizes the probability of error.
Since the operating conditions of nanolayer systems are usually stochastic, modeling the processes occurring in them requires the use of probabilistic methods. The application of the method for calculating percolation by nodes and bonds for solving the problem of stochastic loading of nanolayer structures is facilitated in comparison with those usually used in various physical and technical problems. In this case the impact is not carried out at the boundary of the two-dimensional region of the nanomaterial, with the finding of stresses and strains inside the layer. Instead, stresses and strains are determined in the very surface layer of the material under the influence of an external load. Here we show that with an increase in the number of nodes and bonds in the system, the development of a crack is slow down and that the use of layered systems with a superlattice crystal structure, with minimized internal residual stresses, can provide increased crack resistance.
We propose a method for detecting the boundaries of the cutting edge and flank surface of helical drills.To implement the proposed method, the drill is installed in a rotating holder on the coordinate measuring machine and the rotation around the axis and simultaneous recording of video from the transmitted light camera to create a sample of images, the processing of which determines the profile boundary in the axial section of the drill. To evaluate the accuracy of this method, comparisons of the data obtained with the algorithm and the measuring machine are given. To find the gradient drop zones, the Canny's method was improved with discrete smoothing processing of a sequential set of images while changing the angular position of the drill. In this case, the new method is relevant for real-time image processing with a specified accuracy of up to 5 µm and 30 minutes for linear and angular measurements.
Nanostructured Ti-TiN coatings are one of the most common types of wear-resistant and corrosion-resistant coatings of machine parts and cutting tools. Multicomponent nanostructured coatings were deposited on AISI 318 substrates by vacuum-arc spraying by ion flux ratio for 30-45 seconds with formation of three types of Ti-TiN coatings: three-layer coating, multilayer coating and nanostructured coating. We propose to use the technology of Ti-TiN multilayer coating based on surface modification of the sample by bombarding with a high-current discharge using a “PINK” plasma generator, heating the substrate with ions of cathode material and obtaining cathode material condensation on targets followed by formation of multilayer coating. Target bombarding with an additional ion flux creates active nucleation centers where adsorption occurs and a fine-grained structure is formed. Ion bombardment significantly affects the physical and chemical properties of the sample surface. A detailed research of the change in the relationship of microhardness and adhesion strength of the coating depending on the type of coating of the sample was conducted, and corrosion resistance and wear resistance were investigated by high-precision signal processing from an automatic friction tribometer at a speed of 127 rpm for 60 minutes. As a result of data processing of measuring instruments during control of tribological and physical-mechanical characteristics it was established that formation of nanostructured coatings Ti-TiN with smaller thickness of Ti-TiN layer (30-100 nm) with submicrocrystalline structure allows to improve significantly physicalmechanical characteristics of samples.
Rationalizing energy consumption in the Electrical Discharge Machining (EDM) efficiently saves energy and improves machining quality. Since the conventional methods for estimating useful EDM energy are based on theoretical heat transfer studies or empirical assessments of processing conditions, the development of an industrially applicable method for assessing useful energy is an important problem. Here we show that the performance of the EDM process is directly related to acoustic emission (AE). The effectiveness of the proposed method has been evaluated in experiments. As part of the execution of the experiment, AlCuMg1 workpiece was machined using a copper electrode with different duty cycles with pulse widths varying from 10% to 80%. For comparative analysis, the root-mean-square vibroacoustic signal in the range of 1-10 kHz and the root-mean-square of the discharge current were used. It was found that the amplitude of the vibroacoustic (VA) signal monotonically increases with the increasing EDM performance. The properties of the VA signal allows using the VA monitoring to assess the performance of EDM, i.e., to determine the fraction of energy spent on removing the workpiece material. The advantage of the proposed method of monitoring is that the control of useful energy is carried out using accelerometers installed on the parts of the technological system on the workpiece side. The distance from accelerometers to the workpiece being processed can be quite large that is convenient for performing experiments. In particular, in the high frequencies range, the obtained results are protected from mechanical interference coming from drives, hydraulic units and wire rewinding mechanisms. Such VA signals are shown to be important indicators of EDM efficiency because they are observed only if the energy fluxes reach the workpiece surface. This provides a more reliable indication of raising concentrations of electroerosion products that prevents short circuits and breakage of wire electrodes.
The resistibility to corrosion of biocompatible metals is significantly reduced when plastic deformation of the surface layer is more than 0.5%. To increase the successful reliability of consolidation of bone tissues is proposed to use implants made of chemically pure titanium with a nanostructured biocompatible Ti-TiN coating to improve functional properties. An increase in functional properties is provided by improving coating deposition technology in an arc discharge plasma, which does not allow the formation of any impurities. The use of a high-current diffusion discharge in a vacuum chamber forms a controlled microstructure and the morphology of the implant surface, which increases adhesion during healing. The effectiveness of the proposed coating of implants is proved by the results of comparative tests on the study of the functional properties of samples without coating, with a coating applied by traditional technology and improved technology with a high-current diffusion discharge.
The research presents the principles of development and practical implementation (including rational modes) of combined treatment technology for the surface of precision parts with a broad beam of ions and/or fast argon atoms. In a single technological cycle, two process stages are realized: polishing with a beam at an incidence of 80º to the surface of parts made of different material, which enables a precision level of the surface roughness and deposition of protective nanostructured films on the parts immersed in dense plasma produced by magnetron sputtering in a mixture of inert and reactive gases. The developed innovative technology has a wide range of technological applications, but a particularly promising area is the processing of optical parts and elements.
The article deals with the results of the study focused on the pattern of the distribution of heat flows in the cutting wedge of a carbide tool during the turning of steel. The influence of the wear-resistant TiN, (TiAlCr)N, and (AlTiCr)N coatings on the thermal state of the tool has been investigated. The results of the mathematical modeling have been compared with the data obtained by a method that relates the temperature in the cutting wedge of the tool to the changes in the microstructure and hardness of the material (the Wright and Trent methods). The experimental studies of tool life of the tools with the coatings under study and uncoated tools were carried out during the turning of AISI 5135 steel. It has been found that a tool with the (AlTiCr)N coating has the longest tool life which may be associated with a rational distribution of heat flows in the cutting zone and the cutting wedge of the tool. The use of self-organising wear-resistant coatings reduces the level of temperatures in the cutting zone by 8-20%.
The rapid development of new technologies employing laser, electron beam, electroerosion and other processes as the working ones requires new approaches to developing systems controlling operations being performed. However, these processes do not lend themselves to visual observation and do not allow the introduction of any sensors into the working process zone, which suggests that vibroacoustic diagnostics methods should be used. The article discusses obtaining information from a vacuum chamber under electron-beam action on thin films of reinforcing coatings. It is shown that the parameters of vibroacoustic signals accompanying the formation of new structures can be recorded with the help of flexible waveguides in the form of a wire drawn from a vacuum chamber to a plate with an accelerometer. The article presents and discusses monitoring the formation of intermetallic compounds under the influence of a pulsed electron beam on an aluminum plate covered with a thin film of a heat-resistant nickel alloy.
Toroidal end mills have great industrial applications and have good prospects for increasing the volume of products produced with them. It complicates the process of measuring the cutting edges by changing the position of the cutting edges along the axis, which does not allow the geometry control at the same focal length. The method proposed in the article is an effective tool for carrying out automated measurements of the shapes of cutting edges. Application of the method is relevant for edge control in automated mode. To assess the accuracy of the proposed method, it was tested on a high precision measuring machine Walter Helicheck Plus. The new method allows for repeatability of measurements down to 1.5 μm, which meets the accuracy requirements for non-profiling areas of end mills. Suggested method is universal and can significantly reduce the laboriousness of measuring multi-flute cutters. The most important advantage of this method is the ability to determine the ranges in which there is a smooth cutting edge in all areas of the cutter's cutting edge.
Today, industry is accelerating the use of laser technologies. Laser technologies are one of the areas of material machining with high-energy energy flows. This actualizes monitoring of the performance of laser technologies, because it creates the preconditions for similar research in other areas. In this article, we present the results of experiments that make it possible to determine relationships between the vibroacoustic signals accompanying the action of laser pulses on a workpiece, and the intensity and duration of individual pulses. Analysis of experimental data has lead to identification of the main mechanisms of the formation of wave processes in the workpiece exposed to laser pulses and became the foundation for assessing the role of sublimation processes. The results obtained in this work can be used to develop monitoring system of laser processing for use in automated control systems.
The helical groove, which has a complex shape in the radial section, strongly affects the performance of solid ceramic mills. The accuracy of shaping is strongly affected by the size of the grinding wheel and the kinematic parameters of its movement and rotation relative to the workpiece. Although it is possible to obtain the aforementioned properties using the existing methods, there does not exist a general approach the determination the acceptable ranges of the diameter of the grinding wheel and radius of curvature of its profiling section. In this paper we have analyzed the main features of the design of the profiling sections of grinding wheels, have formed a set of initial parameters that most efficiently implement the trajectory of the shaping movement, which in turn constitutes a new general method of shaping for the helical surfaces of ceramic cutters, have analyzed the character of rolling of a set of profiling sections on a helical surface, have derived new analytical relationships determining impacts of the grinding wheel design and parameters controlling the trajectory of the grinding wheel movement on the shape of the cutter profile in the axial section, and have demonstrated advantages of the developed general approach in designing a new ceramic mill. The new method of shaping allows to unambiguously realize movements of the grinding wheel on various machine layouts and to exclude the displacement of the shaping point by replacing rotation with displacement. Further development of this method will make it possible to replace five- coordinate machines with four-coordinate ones when manufacturing milling cutters with a helical surface that can significantly reduce the production costs.
Solid ceramic mills with a toroidal cutting surface are playing an important, steadily growing role in manufacturing products made of heat-resistant materials. However, properties of these mills have a drawback such as the low strength and, hence, their design requires the absence of zones with high concentration of stresses to reduce the probability of the brittle fracture. In this paper, a new approach to the formation of the cutting edge of solid ceramic end mills has been developed. Unlike the existing approaches, which are based on the shape of the helical groove on the periphery, the new approach is based on the shape of the cutting edge on the toroidal cutting surface determining the shape of the helical surface of the cutter on the radial section. The new method allows finding ranges, in which constant angle cutting edges in the toroidal region exist, and developing multiple new designs of solid end mills with varying combinations of geometric parameters. One of the most important advantages of this method is the ability to determine the ranges, where a smooth cutting edge in all areas of the cutting part of the cutter exists. The derived analytical dependencies can be used to develop new designs of tools of a special shape with a rational combination of geometric parameters of cutting edges with accounting for the radii of the torus surface and the radius of the cutter.
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