Актуальные проблемы в машиностроении. Том 13. № 1-2. 2026 Инновационные технологии в машиностроении ____________________________________________________________________ 47 HYBRID TECHNOLOGY FOR MANUFACTURING PUNCHES WITH INTEGRATION OF MACHINING, INDUCTION HARDENING, AND FINISH GRINDING ON A SINGLE MACHINE BASE Chernikov A.D., Post-graduate Student, junior researcher. e-mail: chernikov.2015@stud.nstu.ru Novosibirsk State Technical University, 20 Prospekt K. Marksa, Novosibirsk, 630073, Russian Federation Abstract The paper presents a hybrid manufacturing technology for critical parts such as punches made of U8A (0.8 % C) tool steel. The technology integrates preliminary milling, surface induction hardening using high‑frequency currents, and finish abrasive grinding within a single machining cycle on a retrofitted five‑axis machining center. Functional relationships between the hardened layer depth and the relative width of the transition zone versus specific heating power (qs = 1.0–4.0 × 108 W/m2) and inductor travel speed (Vs = 1–100 mm/s) were established through a full factorial experiment and numerical simulation using ANSYS and SYSWELD software. Rational hardening parameters were determined: qs = 2.5 × 10 8 W/m2 and Vs = 78 mm/s, yielding a hardened layer depth of 0.52 ± 0.03 mm, microhardness of 840 ± 20 HV, and compressive residual stresses up to 850 MPa. It is demonstrated that a 20‑second spark‑out operation after grinding reduces surface roughness to Ra = 0.197 ± 0.021 μm and increases microhardness to 910 HV due to work hardening of the surface layer. The residual stress distribution with depth was investigated: maximum compressive stresses are localized within the 0–0.1 mm surface layer, while tensile stress zone is shifted to a depth of approximately 0.9 mm. The developed technology reduces the total punch manufacturing time by a factor of 1.9 compared to conventional multi‑machine routing and completely eliminates grinding burn defects. The results were validated in an industrial environment on a batch of 150 parts. Keywords hybrid machining, induction hardening, grinding, residual stresses, sparking‑out, technology integration, numerical simulation
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