Professional Documents
Culture Documents
(MSTU. Bauman)
A manuscript
processing
Scientific adviser -
SV Rude
Moscow 2016
2
TABLE OF CONTENTS
P.
PRODUCTION SPACESHIP
1.1. Identify key areas of the CCI and the ways to increase
eleven
the effectiveness of their training. ...................................................... ..
industry .................................................................................... .. 21
1.5.1. Analysis of calculation of the available options and the contact forces
P.
structure ........................................................................ 64
3.4.2. Development Program (Trailer_mill) and the calculation of the cutting forces,
workability HIGH
P.
4.2. Study of the dependence of roughness on the cutting mode ... ....... 95
4.3. machinability study on cutting force ... ... ....... ......... 105
LIST OF ABBREVIATIONS
CD - design documentation
TD - technical documentation
TP - technological processes
RN - booster
OK - Orbiter
QC - spaceship
product)
TC - technological system
OC - machining center
INTRODUCTION
It depends on the decision of the technological base of modernization tasks, methods and
years before the JSC "ZEM" RKK "Energy" as a parent company for
process module;
various applications.
Research methods.
and in the actual production conditions in the processing of the body segment
IN TO.
Scientific novelty:
Developed and approved instructions for the CCI components with VKO, the main
which will be called the key, as well as state and ways to improve
needed for the production of products with established technical and economic
We will adjust based on the design features of the new ship and
(Fig. 1.1). Based on the analysis, one can identify the major
milling).
It should be noted that over the last 8 years with a continuous input in
Tests are carried out for both individual parts and for components and manufacturing
More than 15% of the complexity of the product is occupied at the moment
take into account the fact that the production of aerospace hardware mainly
single or small-scale.
parts of the housing and traffic along the seam of the welding head.
Used assembly and welding technologies are constantly being upgraded and
coatings.
14
The spacecraft during descent from orbit, passing through dense layers
of the vehicle from damage and destruction due to this influence, the outside
specified intervals.
aluminum alloys in the housing parts and the details of the power set requires
The use of a wafer shell design of the new ship's hull makes
It is necessary to take into account the fact that the complexity of the mechanical structure
technology.
One of the main technologies for the production of the ship, of course,
It is expected at the same level 14% of the total complexity of the product.
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
due to changes in the size of the new ship, compared with the ship
the volume of which in the manufacture of products already mastered much lower. AT
Analysis of the amounts (Table 1) and define the direction key CCI
Table 1.
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
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
The main ways of increasing the efficiency of the CCI a new ship
look at two:
known path that has proved its relevance and necessity of having
personnel. However, from the point of view of the CCI implementation of new equipment,
a significant reduction in the complexity of the CCI. For example, the presence of 5-
RKT products from the time of conclusion of the contract until delivery of the object in orbit.
automation.
technologies.
production of goods
21
basic steps:
- product design;
- rationing;
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
under development in the second half of the twentieth century, and actively
the addition of the machine. The basic principle is that the product
22
use additive technology simply much more efficient. After all, they
allow to produce details of products, tools, and even the whole assembly.
(Fig. 1.5).
Fig. 1.5. Schematic diagram of the process of making an article sample [3]
23
composition makes sense for large volumes. Third - not investigated before
should not forget that the cost of manufacturing parts by SLS yet
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
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
JSC, JSC "NPO Saturn" "Aircraft Engine", AKB "Anchor" (Fig. 1.6). [4]
24
Fig. 1.6. Examples of the parts produced by the method for SLS
Russian companies
the use of such shells in the country recorded in the early 1960s
100.
In the process of designing the tanks of these missiles for the first time in the country
under axial compression than equal by weight to them smooth [6]. A construction with
25
particularly relevant for rocket and space technology, where important and
(Table 2).
and continued on. Besides SD-200 (diameter: 3000 mm, sheet thickness of 16 mm,
In addition to fuel tanks missiles, there are other applications with facts shells
It consists of a shell, six frames, the front and rear ends, upper and
welding [7].
Table 2.
Methods for producing wafer shells with their construction and applicability
ed in exactly
Note
method number st Experience of Material
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
cabin
Spacecraft "Orion"
housing
Currently, topical was the question of the use of the shell with
manned spacecraft. Russia (Fig. 1.8, the PTC-NP) and the US (Fig.
IN TO.
also at small dimensions of the shell calculated dimensions (thickness of the wall,
CT may have a different shape and size, and the share of milling
With the same purpose, the housing parts are designed maximum CT
tool manufacturers.
may have a complex configuration, deep pockets and thin walls (Fig.
design.
1.5.1. Analysis of calculation of the available options and the contact forces
parts
milling the housing parts possible deformation of the walls and bottom of pocket
These activities, for example, relates to control of the cutting force during
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,
x
FK
r
ah Krpa, re p (1.2)
t
. te- .coefficients
KKKK r
. Re are established experimentally.
32
[19, 20]. The main drawback of these sources is the fact that these
Cutting through specific effect [21]. According to this method, any kind of
It is defined as
(1 ) m
F cbhK K bhc k cK,
f eleven f
(1.3)
K f - correction factor;
m - exponent.
The disadvantage of the expressions (1.1), (1.2), (1.3), as well as the degree of the equation
summarize the results of the experimental data and are valid for
Applied Physics. The method consists in the fact that the area (one-, two-,
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.
thin-walled parts, and also to evaluate the accuracy of the milling treatment on
recently.
[23], estimates the amount of elastic deformation cutter from contacting the workpiece
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
./ .
Elemental analysis calculated with the load. In addition, you should not
forget that the empirical expression [23] is only suitable for calculating at
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,
businesses, where it is held, and, in spite of the general similarity, the process
In accordance with the purpose of the work the following tasks have been set:
technology.
in the general cycle of the product development process takes a significant part
task was to check the spread of the hypothesis that the effect on
It puts forward that the costs of the loss of information when pairing
the costs caused by the weakness of any functions in any given system.
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
When working within the parallel loop-through (Fig. 2.1) at the expense of
scheduling to the time of closure of the product development in the form of 3-D
All information has been prepared for the transition to the second stage through
parallel loop.
released product drawings, which allows you to make the manufacture and
The diagram (Fig. 2.2) shows the reduction of the period of the Design
parallel loop.
According to the results of this work may be noted that the use of
electronic
Difficulty - Table 3
42
Table 3.
Classification of details according to the type and complexity of the group in agreement.
parts
Group
Woodturning milling
difficulty
parts
Group
Woodturning milling
In the figure, 100 sizes. Details are: In the figure, 200 sizes. Details are:
transmitted leading engineer (or the head of the Bureau) for verification. Second
this process.
stages Time, days processes
1 2
metrological
3 1-2
Technical inspection
workshop Checking
matching
4 2-3 control (BTK)
5 2-3 rationing
Coordination with
6 2-3
approved
giving
Chief
8 1-2 Specialist
2 Technical department
September
14-21 shop Archive Archive TP
- parameters to be measured;
- measurement means;
- Conditions of measurement;
(Head of Department).
inventory number and is the official copy for the department. Original
remarks. The time required for this process may reach 14-21 days.
conducted in accordance with established procedure and standard, this process does not require
poor control over the execution and the lack of agreed and approved
1 2
metrological
inspection normative control
control
PDM Windchill control
June
7-14 Archive TP shop Archive
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
This technologist starts the approval procedure and the message (letter) on
Working at the same time, they have the opportunity to make their corrections to the
47
documentation.
revision.
In the third step records again enters directly the 2nd participants
to approve.
Tc TK
i
*. i (2.1)
i 1
T i
; T;
T ISM sc TKNT ; T; nb
T; T; G is . (2.2)
coordination;
any time can be seen at what stage is the documentation and who have
From the diagram (Fig. 2.5), which shows the comparison of time indicators
Chief BTK;
documentation;
design STO
the manufacture of such kinds of equipment as frame templates, copiers and others.
[35].
These nodes are used to transfer liquids and gases under pressure from one
assembling and soldering beam USP are used to collect all of the standard "beam" of
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."
"Beams";
working skills).
process complexity and high labor intensity, the work requires specialist
Start
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)
the end
technologies
53
construction;
the use has been proposed for solving these problems of additive
combined with the technology of digitalization of physical objects and the subsequent
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.).
sintering
55
specific modification process and the material used), and after leaving
It acts as a natural support. The working process takes place in a nitrogen environment and
the end
technologies
56
1 2
3
4
Fig. 2.11. The proposed assembly technology "beam" using the method
At the last stage the individual lines are installed on the USP in
assembly-brazing "beam."
results:
(A decrease of 60 N / h, 65%).
prototype EMI.
formed at the intersection of cell and executed with the web as the
integrally [39].
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
mm.
is presented in Table 4.
Table 4.
industry AMg6 alloy that must be taken into account in the assignment mode
[43].
G - geometric dimensions;
IT - dimensional tolerances;
ra - surface roughness.
Kp Hp Sp, / (3.2)
KD ld sd, / (3.3)
high strength aluminum alloy, the tolerance on the thickness of the bottom and edges of 0,2 mm,
Table 5.
Workability
manufacturability limitedly low-tech
kp <15 15 - 30 > 30
cd <40 40 - 60 > 60
processing;
analytical work in order to avoid deformation of the bottom pocket of the cutting forces.
design
Based on the geometry and material of the workpiece being processed, select
Plunging strategy and machining of pockets are well known, their choice
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.
closed loop:
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".
the time of transition to processing for applying a predetermined working depth of the passage
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
the bottom surface of the pocket. Suitable for most modern mills,
Ds
Dr
- plunge "twist on a path" (Figure 3.7.) - the movement of the cutter on the 3rd
processing.
Ds
Dr
Dr ds
well, and the trajectory of the cutter motion for "equidistant" policies and
smallest path length, however, and the minute feed is much lower
than that of the next two strategies. Strategy "spiral" and plunge
(Table 6).
movement of the cutter with smooth load variations, allowing you to work on
cutters.
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
in the direction of reduction. With such a strategy, as a rule, it takes the last
Table 6.
plunging strategy
Strategy "Spiral
"Vertical" "Spiral"
Criterion the contour "
Rotation frequency,
1200 6000 6000
rev / min
Cutting speed,
60 300 300
m / min
loop in one direction, with the shift by the amount of cutting depth after
for each subsequent insertion by the amount of shear cutting depth (Fig.
pocket.
the contour of the pocket, with a shift in the depth of cut from circuit to circuit (Fig.
movement along the contours and load changes during the transition from circuit to
rounding path
70
load jumps and application functions fillet radius at the corners of administration
- "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
administration functions the rounding radius in the corners also allows the trajectory
In most cases, it does not require finishing pass along the contour
rounding path
take the "spiral" with the function of the introduction of the radius of curvature as a strategy,
Table 7.
Strategy
Criterion
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
(Figure 3.11.):
- 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.
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
- based on the calculation algorithm to develop a program for calculating the forces
- with the help of the developed program to obtain the values of cutting forces and
parameters.
3.4.1. Calculation of forces and the contact loads when milling end
the basis of calculation used a technique developed at the Department of MT-2 Bauman
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
.
auxiliary angle in plan, 1. respectively. Cutter handles groove
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
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
The width of the helical tooth edge on the cylindrical portion of the cutter b ( 3.4)
2 2
d H tg 0
b ( B rd )
2 2
. (3.4)
angular coordinate i.
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
as sin cos
z 0 . (3.6)
0- contact angle.
as cos
z . (3.7)
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
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.
a s z sin ( 1)
j
. (3.10)
Separate the edges: screw 12, radius 23, the end 34 (Figure 3.14.).
sectional edge has a rounding radius . a point A divides the slice thickness
R angle of action
shaving instrument side to a force c to
Fig. 3.13. The scheme for calculating kinematic parameters and cutting layer
expression takes into account the influence of the parameters of the shear layer and the elastic
1.08 ( 4
E1ba/) Cos sin
/ 2 arctg
cos sin
. (3.11)
77
materials;
12 - Poisson's ratio;
and the angle of action between the resultant force on the front
proposed in [49-50]:
tg ( )
/4 ' . '
tg ( ) 2. (3.14)
used to calculate the phase angle for turning by one of the authors
[51].
shear plane P
P p ab
Rc . (3.15)
sin () cos ( ) Sin () cos ( )
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)
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
Where m - relative distance from the cutting edge along the front surface of the tool.
The contact pressure has a maximum value at an arc length AB, which is determined by
P mm AB b.
(3.23)
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.
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
Cutting along the axis Z, you can calculate the total torque cutting
(3.28)
MMMM,12 3 34 (3.28)
- screw
dz p
M 12
( RPF
cz mz 2 ) Year . (3.29)
2000
- front
R jz pj
M 34
( R czj P mzj F 2 j ) 1000 . (3.31)
edges that make up the cutting forces are determined by (3.18) (3.19) (3.24) (3.25)
(3.26) (3.27).
N Mn / 9554 . (3.32)
In accordance with the scheme of Fig. 3.13 tool has tooth blade
value z h and the arc of the cutting edge AB. Here it is assumed uniform
3.4.2. Development Program (Trailer_mill) and the calculation of the cutting forces,
milling (A.1). To this end the source data defined for the selected
Aluminum alloy (01570S) and grade cemented carbide (VK6M) - (Figure 3.15.):
t - cutting depth;
other parameters. The calculated parameter values are displayed on the form
Fig. 3.15. Trailer_mill calculation program interface: the left - the raw data;
Right - results
82
calculation and analytical works in order to avoid deformation of the bottom pocket of strength
pocket bottom.
Using Trailer_mill program will calculate the force acting on the bottom
cutting conditions on the force acting on the bottom of the pocket, will affect the angle
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
shear layer at the final instant infeed B = 1 mm, t = 16 mm, the tool -
[53], we calculate the force acting on the bottom of the pocket at the final instant
The calculation is performed for supplying the values S z = 0.05; 0.083; 0.1; 0.15; 0.2
obtained in the calculation (see. Table 8 ... 13), used for loading
stress.
processing the bottom of his pocket, and recommendations for treatment regimes
Table 8. Table 9.
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
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
CAD CATIA.
5 6
4
March
in accordance with the results of the calculation of the forces and the diagram in Fig. 3.12. Through
bottom (Fig. 3.21), and equivalent stress (Fig. 3.22). The values obtained
According to the results of calculation of forces and loading models with waffle
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
, mm
1 ,
eq, Mpa
t = 245
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.
Currently infeed reaches 0.18 mm, which is also not lead to failure of tolerance
EKR cells.
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.
edges in Trailer_mill program. This is due to the fact that the value of
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
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
is not involved, since allowance has been removed edges 23, 34 and 56,
pocket defined parameters (Fig. 3.2) and in specified conditions will range
processing modes that fall within the zone 1 and the zone 2
wear on the cutter rear surface is not more than 0.1 mm.
91
design
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
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
different values KD
from KD less than 40 is not limited due to the absence of significant deformations
bottom.
1.32
Sz 0.62 . (3.34)
which includes the calculation of forces when cutting in Trailer_mill program in conjunction with the
waffle design
Fig. 3.24. Method of optimization processing technology with the housing part
IN TO
94
ALLOYS.
processing.
We will use:
B - milling width,
t - milling depth,
RSC "Energy" and in the laboratory of the department "Technology and Instrumental
Fig. 4.1. The process of measuring the surface roughness on the end of the groove on
portable profilometer Mitutoyo Surftest SJ-301
96
specific cutting conditions. For each slot provided for the measurement of
roughness parameter Ra (according to the 3rd measurement) on the end face and
3) The end mill 16 mm diameter Guhring 16.0 z = 3202 4 (Figure 4.4.) [61];
aluminum alloys.
where the fixed one of the parameters of cutting conditions (speed in turns
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
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-
Fig. 4.5. Plots of the roughness Ra of the side walls and end
Fig. 4.6. Plots of the roughness Ra of the side walls and end
Fig. 4.7. Plots of the roughness Ra of the side walls and end
Fig. 4.8. Plots of the roughness Ra of the side walls and end
less Ra5mkm (class 5), in the processing of the step - less Ra2mkm (class 6).
- OC TOYODA FH550SX
- groove processing
The results of a series of experiments for the team end mill (Fig. 4.11,
Fig. 4.9. Plots of the roughness Ra of the side walls and end slot
from s z when n = 5100 rev / min
minute spindle rotation and feed for each cutter during processing
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
spindle are limitations that need to be taken into account in the implementation of
this will ensure a more productive process with the lack of a stable
indicators:
- process performance
2. Dynamometer UDM-600
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"
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.
Fig. 4.19. Depending on the components of the cutting forces from the minute feed at
AMg6 01570, V1469 in the same conditions, we introduce the force factor
Fig. 4.20):
different feeds;
Fig. 4.20. Depending on the cutting force of the minute feed during processing
element "wall" for 3 aluminum alloys
cutting forces.
110
cutting force coefficient K R ( 4.2) under the same conditions above to 13-27%.
on the cutting force for the three aluminum alloys (Fig. 4.19, 4.20).
Table 14.
Mechanical properties
Coefficient of alloys
number Alloy
cutting force TO R AT, 0.2
,%
MPa MPa
However, for the treatment of long-term product shell RKT this question
with 1,200 pockets predetermined size (Fig. 4.21). Calculate the time
CT (taking into account the recommendations of the instrument manufacturer companies, the results of
Fig. 4.21. Modeling of processing the body part of the new ship
rev / min;
Cutting data:
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)
n - number of pockets.
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 .
details of this can lead to the disruption of timing of the launch of the spacecraft with
instrument without loss of precision parts size [66]. Given the large
dimensional stability, and to calculate the required number of cutters for processing
products. In addition, the same mill was used in the processing of the model
Table 15.
01570S;
Width: B = 5 mm;
Depth: t = 8 mm;
The total operating time was 498 minutes milling, with the milling cutter
surface reaches 0.12 mm, the wear on the back surface of the auxiliary
wear.
114
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
T Fr. .
T exp .
* TOs 498 0.8 398 * min, . (4.5)
WhereT Fr.
- maximum
.
time to replace the cutter;
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.
casing is 19 pcs.
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
CCI directions.
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.
This is due to including the fact that for the development and operation
it is not always immediately possible to implement. After setting up the system, Adaptation
Table 16.
The actual
End date Standard
difficulty Date of the
Item number matching time, days
Group commencement of negotiation negotiation,
days
- Delays - with
delay - on time
118
Insertion strategies: the contour of the spiral, vertical and spiral (Fig.
5.2) in the final moment of incision. Effort for helical insertion was
240N.
Figure 5.2. Force values for plunging acting on the bottom of the pocket
plunging to the bottom of the pocket, you must apply the Insertion strategy
"Twist on a path."
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-
Fig. 5.4. "Element waffle design" and the part on the machine table
121
obtained in 4.2.
4.2.2.
Table 17.
The results of the roughness measurements of the treated surface of the part
The relevant parameters section layer cut and the cutting conditions
Table 18.
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
It showed that the surface roughness is also within Ra <1 mm, and details
Ra1mkm).
Table 19.
The results of the roughness measurements of the treated surface of the part
"Frame"
actual size of the aluminum alloy plate (01570S) (Fig. 5.8) [69].
Processing performed on the cutting conditions and with the use of strategies
We need to study the action of cutting forces at the bottom of the finishing infeed
bottom.
(Fig. 5.9) the forces acting on the bottom insertion during finishing, in accordance with
T mung .
T karmas
n K. xk
6.19 * 171 * 0.99 1048 min
127
Table 20.
Parameter Value
cr 7.5
cd 50
S, mm / min 1200
Bxt, mm 5x5
S, mm / min 1200
Bxt, mm 1h16
insertion angle 9.
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
comparable to the characteristics of the segment model, and at the same time simplifying and
central pocket, all the side of the model set out in tight seals, bottom
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
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 bottom of the calculation by finite element method in CATIA CAD (Table 11)
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
irregularities formed on the surface of the parts during their processing, are
Stamina [70].
132
EXECUTIVE SUMMARY
144 n / h.
object - the body part with VKO, including the organization of CCI, analysis
(TO p < 30) and the bottom (K d < 60) which are technological limitation in
the bottom of the pocket of East Kazakhstan region for finishing, is plunging strategy
"Twist on a path."
promising products.
technological instruction.
134
BIBLIOGRAPHY
S. 41-44.
http://www.stankin.ru/science/scientific-educational-centres-and
5. Katz IL For the history of the design, method of calculation and examples
URL:
http://www.mscsoftware.ru/document/conf/Moscow_conf/conf_2001/Khrunich
Treatment 25/05/2016).
135
12. Stability limits of milling considering the flexibility of the workpiece and the
regulate tool life in end milling processes // Precision Engineering. 2010. 34.
P. 675-682.
14. Rott O., Homberg D., Mense C. A comparison of analytical cutting force
286 p.
milling / RPH Faassen [et al.] // International Journal of Machine Tools &
19. Cutting data for turning and drilling, milling and boring
group.com/fileadmin/catalog/en/BK_ZHB_2009_en/blaetterkatalog/index.html
choice of cutting conditions in the exact instrument making and mechanical engineering //
Yekaterinburg: SEI HPE Ural State Technical University named after the first President of Russia
26. Experience in the use of CAD ADEM in the production of rocket and space
100; 2. S. 84-90.
"Process technology". The main provisions. The objectives and tasks of the system. Company
2003. T. 5, 1. S. 55-65.
6. S. 34-36.
S. 7-13.
39. GOST 22350-91. Housing rocket using liquid fuel. terms and
Standards, 1991. 17 p.
Brand. Introduced 7/7/00. M .: State Standard of the Russian Federation: Publishing house "Standartinform"
2009. 15 pp.
"Standartinform", 2009. 4.
45. Guide - CAM module for version 8.0 [electronic resource]. URL:
http://www.adem.ru/assets/files/downloads/rukovodstva_pol'zovatelya/rukovo
05.25.2016).
46. High Speed Aluminum Machining Presentation. The Boeing Company, 2008.
P. 22-24.
1975. 344 p.
49. Rosenberg JA, SI Tahman Cutting forces and methods of their definition:
2-h .: Proc. allowance. Barrow: KMI, 1995. Part 1. General Provisions. 128.
50. Rosenberg JA Cutting of materials: the textbook for tehn. universities. Mound:
2010. 107 p.
01.04.2014).
2 (10). S. 91-94.
manufacturer ISCAR. Israel, 2005. with one thousand one hundred and sixty-two.
1985. 304 p.
10.7463 / 0514.0709770
"Energy", 2015. 35 p.
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
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}
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
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;
procedure ApprocsimB;
begin
if (l1 / l2 = 0) or (l2 / l1 = 0) then begin B_l1l2: = 2.93; B_l2l1: = 2.93; end; // .........
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;
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
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;
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
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);
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
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
gam: = gamsr / N; // take the average value of the front. angle if (BB> r) then
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;
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;
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');
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 (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;
// 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
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');
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
begin
psi0i: = pi / 2;
amaxi: = sz * (sin (tau) * cos (ei) + cos (tau) * sin (ei) * sin (psi0i)); zpi: = psi0i / 2 /
pi * z; end; aai: = amaxi;
end;
end; gam: = gamsr / N;
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);
// end tooth
aaj: = 0; amaxj: = 0; M34: = 0; Pzj: = 0; Rczi: = 0; Pmzi: = 0; F2i: = 0; zpj: = 0; z56: = 0; z78: = 0; psi0j: = 0;
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); // ------------------------
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
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
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
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);
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
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');
COMMENT
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%
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.
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.
Scientific adviser,