OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 5 No. 3 2023 Introduction In industrialized countries, the volume of metalworking products is in the range from 35 % to 40 % of the total production [1–3]. In turn, the industrial sector accounts for more than 50 % of global energy consumption, of which countries outside the Organization for Economic Co-operation and Development (OECD) account for up to 67 %. The use of energy and resources in the manufacturing sector is about 40 % and 25 % of world consumption, respectively. Recently, the concept of ensuring sustainable production is gaining momentum due to the awareness of this enormous ecological impact on the environment through the significant use of energy and resources [1–6]. There is a clear understanding that sustainable growth in production is possible only if the conditions for manufacturing products are realized, under which processes are used that minimize the negative impact on the environment, conserve energy and natural resources, are safe for employees, the public and consumers and are economically justified. Consequently, the success of the development of a particular production largely depends on the effective use of metalworking machines. In this regard, in the strategically important and basic branch of mechanical engineering – machine tool industry – a cluster of hybrid metalworking systems has formed, in the design and creation of which the developers adhere to the principle of multifunctional integration [4, 7–18]. One of the options for this hightech integral equipment is machine tools that combine several technological processes of different nature (fig. 1) (e.g. milling, turning or grinding using various additional energy sources [7, 14, 17, 19–70]). The designers’ pursuance of increasing the technological potential of machine tools and ensure autonomous operation of hybrid equipment in adaptable production has led to the emergence and development of this class of equipment [7–9, 14, 16–21, 32–37, 47]. Industrial testing showed positive results, confirming the production cycle reduction for the manufacture of machine parts and a resource costs decrease when using such systems [7, 10, 14, 20–74]. a b c Fig. 1. Varieties of hybrid metalworking machines that combine machining with various heat sources: a – Induction Assisted Milling (IAM); b – Plasma Assisted Turning (PAT); с – Laser Assisted Grinding (LAG) The current investigation is concerned with the technological process of manufacturing a press brake plug, which includes the following operations: 1) machining, 2) milling and surface hardening, 3) highenergy heating by high-frequency currents (fig. 2). When developing a classical technological process for manufacturing this part, the operations of surface thermal hardening and milling are traditionally carried out on different equipment and in different workshops of a machine-building enterprise. As a result, at the thermal operation it is necessary to obtain a hardened layer of greater thickness than specified by the detailed drawing, and then, at the finish mechanical operation, remove the most effective part of the surface layer. Due to this approach, there is a decrease in efficiency both in the surface thermal and mechanical operations, as well as an increase in energy consumption at both stages of the technological process [7, 14, 17, 21, 47, 61, 71–75]. To solve this problem, it is proposed to combine two operations on one metalworking machine. Taking into account the modern development of microprocessor technology in the field of high-frequency thyristor-
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