Актуальные проблемы в машиностроении. Том 13. № 1-2. 2026 Технологическое оборудование, оснастка и инструменты ____________________________________________________________________ 87 DESIGN AND TECHNOLOGICAL PRINCIPLES FOR CREATING A HYBRID MACHINE SYSTEM BASED ON A CENTERLESS GRINDING MACHINE THAT INTEGRATES GRINDING AND SURFACE HARDENING USING HIGH‑ENERGY HIGH‑FREQUENCY INDUCTION HEATING (HEH HFC) Rozhnov E.E., Post-graduate Student, junior researcher, e-mail: rozhnov.2017@stud.nstu.ru Novosibirsk State Technical University, 20 Prospekt K. Marksa, Novosibirsk, 630073, Russian Federation Abstract The manufacture of axi-symmetric components — pins in particular — necessitates the sequential execution of surface hardening followed by finish grinding. In current industrial practice these operations are carried out on separate machine tools, giving rise to a well-documented chain of inefficiencies: inter-operational transfer, repeated workpiece datum setting, intermediate cooling, and the consequent accumulation of setup errors coupled with an unjustifiable increase in energy consumption. Actual material removal accounts for only a fraction of the total cycle time, while a substantial share is expended on auxiliary non-value-added transitions unrelated to geometry generation. The present work substantiates a design-and-process approach that enables the integration of centerless grinding and high-energy induction heating (high-frequency current-based) within a single machine–tool complex. The concept of combining heterogeneous process actions is not in itself novel; however, its engineering implementation as applied specifically to centerless grinding machines has until recently remained insufficiently developed. The proposed solution does not entail the design of fundamentally new equipment but rather involves the purposeful retrofitting of production-series centerless grinders through the incorporation of an induction heating module. This route is considered economically viable, given that the installed base of grinding equipment at domestic manufacturing enterprises is extensive yet remains substantially underutilized. It is demonstrated that integrating thermal and mechanical actions within a single setup eliminates intermediate workpiece cooling, precludes the need for reheating, and markedly reduces the overall production cycle duration. Equally important, the prompt transition from hardening to grinding facilitates the preservation of the surface-layer microstructural state produced during heat treatment, thereby exerting a beneficial effect on the service performance of the finished component. The design-and-process principles governing the construction of such a hybrid machine-tool system — capable of performing hardening, tempering, and finish grinding in a single setup — are formulated, and the reserves for intensifying the production of pin-type components afforded by this approach are delineated. Keywords hybrid machine tool system; centerless grinding; high-energy high-frequency induction heating (HEH HFC); surface hardening; grinding; hybrid equipment.
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