Vol. 24 No. 4 2022 3 EDITORIAL COUNCIL EDITORIAL BOARD EDITOR-IN-CHIEF: Anatoliy A. Bataev, D.Sc. (Engineering), Professor, Rector, Novosibirsk State Technical University, Novosibirsk, Russian Federation DEPUTIES EDITOR-IN-CHIEF: Vladimir V. Ivancivsky, D.Sc. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Vadim Y. Skeeba, Ph.D. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Editor of the English translation: Elena A. Lozhkina, Ph.D. (Engineering), Department of Material Science in Mechanical Engineering, Novosibirsk State Technical University, Novosibirsk, Russian Federation The journal is issued since 1999 Publication frequency – 4 numbers a year Data on the journal are published in «Ulrich's Periodical Directory» Journal “Obrabotka Metallov” (“Metal Working and Material Science”) has been Indexed in Clarivate Analytics Services. We sincerely happy to announce that Journal “Obrabotka Metallov” (“Metal Working and Material Science”), ISSN 1994-6309 / E-ISSN 2541-819X is selected for coverage in Clarivate Analytics (formerly Thomson Reuters) products and services started from July 10, 2017. Beginning with No. 1 (74) 2017, this publication will be indexed and abstracted in: Emerging Sources Citation Index. Journal “Obrabotka Metallov” (“Metal Working & Material Science”) has entered into an electronic licensing relationship with EBSCO Publishing, the world's leading aggregator of full text journals, magazines and eBooks. The full text of JOURNAL can be found in the EBSCOhost™ databases. Novosibirsk State Technical University, Prospekt K. Marksa, 20, Novosibirsk, 630073, Russia Tel.: +7 (383) 346-17-75 http://journals.nstu.ru/obrabotka_metallov E-mail: metal_working@mail.ru; metal_working@corp.nstu.ru
OBRABOTKAMETALLOV Vol. 24 No. 4 2022 4 EDITORIAL COUNCIL EDITORIAL COUNCIL CHAIRMAN: Nikolai V. Pustovoy, D.Sc. (Engineering), Professor, President, Novosibirsk State Technical University, Novosibirsk, Russian Federation MEMBERS: The Federative Republic of Brazil: Alberto Moreira Jorge Junior, Dr.-Ing., Full Professor; Federal University of São Carlos, São Carlos The Federal Republic of Germany: Moniko Greif, Dr.-Ing., Professor, Hochschule RheinMain University of Applied Sciences, Russelsheim Florian Nürnberger, Dr.-Ing., Chief Engineer and Head of the Department “Technology of Materials”, Leibniz Universität Hannover, Garbsen; Thomas Hassel, Dr.-Ing., Head of Underwater Technology Center Hanover, Leibniz Universität Hannover, Garbsen The Spain: Andrey L. Chuvilin, Ph.D. (Physics and Mathematics), Ikerbasque Research Professor, Head of Electron Microscopy Laboratory “CIC nanoGUNE”, San Sebastian The Republic of Belarus: Fyodor I. Panteleenko, D.Sc. (Engineering), Professor, First Vice-Rector, Corresponding Member of National Academy of Sciences of Belarus, Belarusian National Technical University, Minsk The Ukraine: Sergiy V. Kovalevskyy, D.Sc. (Engineering), Professor, Vice Rector for Research and Academic Affairs, Donbass State Engineering Academy, Kramatorsk The Russian Federation: Vladimir G. Atapin, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Victor P. Balkov, Deputy general director, Research and Development Tooling Institute “VNIIINSTRUMENT”, Moscow; Vladimir A. Bataev, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Vladimir G. Burov, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Aleksandr N. Gerasenko, Director, Scientifi c and Production company “Mashservispribor”, Novosibirsk; Sergey V. Kirsanov, D.Sc. (Engineering), Professor, National Research Tomsk Polytechnic University, Tomsk; Aleksandr N. Korotkov, D.Sc. (Engineering), Professor, Kuzbass State Technical University, Kemerovo; Evgeniy A. Kudryashov, D.Sc. (Engineering), Professor, Southwest State University, Kursk; Dmitry V. Lobanov, D.Sc. (Engineering), Associate Professor, I.N. Ulianov Chuvash State University, Cheboksary; Aleksey V. Makarov, D.Sc. (Engineering), Corresponding Member of RAS, Head of division, Head of laboratory (Laboratory of Mechanical Properties) M.N. Miheev Institute of Metal Physics, Russian Academy of Sciences (Ural Branch), Yekaterinburg; Aleksandr G. Ovcharenko, D.Sc. (Engineering), Professor, Biysk Technological Institute, Biysk; Yuriy N. Saraev, D.Sc. (Engineering), Professor, Institute of Strength Physics and Materials Science, Russian Academy of Sciences (Siberian Branch), Tomsk; Alexander S. Yanyushkin, D.Sc. (Engineering), Professor, I.N. Ulianov Chuvash State University, Cheboksary
Vol. 24 No. 4 2022 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Dyuryagin A.A., Ardashev D.V. A study of the relationship between cutting force and machined surface roughness with the feed per tooth when milling EuTroLoy 16604 material produced by the DMD method...................... 6 Ulakhanov N.S., Tikhonov A.G., Mishigdorzhiyn U.L., Ivancivsky V.V., Vakhrushev N.V. The features of residual stresses investigation in the hardened surface layer of die steels after diffusion boroaluminizing............... 18 Rubtsov V.E., Panfi lov A.O., Knyazhev E.O., Nikolaeva A.V., Cheremnov A.M., Gusarova A.V., Beloborodov V.A., Chumaevskii A.V., Ivanov A.N. Development of plasma cutting technique for C1220 copper, AA2024 aluminum alloy, and Ti-1,5Al-1,0Mn titanium alloy using a plasma torch with reverse polarity................ 33 Amirov A.I., Moskvichev E.N., Ivanov A.N., Chumaevskii A.V, Beloborodov V.A. Formation features of a welding joint of alloy Ti-5Al-3Mo-1V by the friction stir welding using heat-resistant tool from ZhS6 alloy....... 53 EQUIPMENT. INSTRUMENTS Ardashev D.V., Zhukov A.S. Investigation of the relationship between the cutting ability of the tool and the acoustic signal parameters during profi le grinding..................................................................................................... 64 Bataev D. K-S., Goitemirov R. U., Bataeva P. D. Studies of wear resistance and antifriction properties of metalpolymer pairs operating in a sea water simulator........................................................................................................ 84 Zakovorotny V.L., Gvindjiliya V.E., Fesenko E.O. Application of the synergistic concept in determining the CNC program for turning............................................................................................................................................ 98 MATERIAL SCIENCE Sokolov R.A., Novikov V.F., Kovenskij I.M., Muratov K.R., Venediktov A.N., Chaugarova L.Z. The effect of heat treatment on the formation of MnS compound in low-carbon structural steel 09Mn2Si................................ 113 Burkov А.А., Krutikova V.O. Deposition of titanium silicide on stainless steel AISI 304 surface...................... 127 Pugacheva N.B., NikolinYu.V., BykovaT.M., Goruleva L.S. Chemical composition, structure and microhardness of multilayer high-temperature coatings..................................................................................................................... 138 Saprykina N.А., Chebodaeva V.V., Saprykin A.А., Sharkeev Y.P., Ibragimov E.А., Guseva T.S. Synthesis of a three-component aluminum-based alloy by selective laser melting............................................................... 151 Gabets D.A., MarkovA.M., Guryev M.A., Pismenny E.A., NasyrovaA.K. The effect of complex modifi cation on the structure and properties of gray cast iron for tribotechnical application..................................................... 165 Ivanov I.V., Yurgin A.B., Nasennik I.E. Kuper K.E. Residual stress estimation in crystalline phases of highentropy alloys of the AlxCoCrFeNi system........................................................................................................... 181 Korosteleva E.N., Nikolaev I.O., Korzhova V.V. Features of the structure formation of sintered powder materials using waste metal processing of steel workpieces................................................................................. 192 EroshenkoA.Yu., Legostaeva E.V., Glukhov I.A., Uvarkin P.V., TolmachevA.I., Luginin N.A., Bataev V.A., Ivanov I.V., Sharkeev Yu.P. Effect of deformation processing on microstructure and mechanical properties of Ti-42Nb-7Zr alloy............................................................................................................................................. 206 Kutkin O.M., Bataev I.A., Dovzhenko G.D., Bataeva Z.B. The study of characteristics of the structure of metallic alloys using synchrotron radiation computed laminography (Research Review)................................ 219 EDITORIALMATERIALS 243 FOUNDERS MATERIALS 255 CONTENTS
OBRABOTKAMETALLOV Vol. 24 No. 4 2022 TECHNOLOGY Introduction The fabrication of one-off products or small batches is a distinctive feature of the machine-building industry [1]. Innovative technologies are used to produce such products and the creation of complex-shaped parts is currently one of the most rapidly developing fabrication technologies [2]. Direct Metal Deposition (DMD), a method of local metal deposition, relates to these technologies. In this method, a laser beam generates a molten pool into which a metal powder is injected [3], resulting in the powder being melted with the substrate material to create a strong bond. A study of the relationship between cutting force and machined surface roughness with the feed per tooth when milling EuTroLoy 16604 material produced by the DMD method Alexander Dyuryagin a, *, Dmitrii Ardashev b South Ural State University, 76 Prospekt Lenina, Chelyabinsk, 454080, Russian Federation a https://orcid.org/0000-0001-6274-1953, s.dyuryagin@mail.ru, b https://orcid.org/0000-0002-8134-2525, ardashevdv@susu.ru Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2022 vol. 24 no. 4 pp. 6–17 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2022-24.4-6-17 ART I CLE I NFO Article history: Received: 30 August 2022 Revised: 06 September 2022 Accepted: 21 September 2022 Available online: 15 December 2022 Keywords: End milling Cutting force Roughness of the machined surface Direct Metal Deposition EuTroLoy 16604 Funding This research was funded by Ministry of Science and Higher Education of the Russian Federation (grant No. FENU2020-0020). ABSTRACT Introduction. Currently, a substantial proportion of the machine-building industry is made up of one-off products or products manufactured in small batches. In this regard, innovative approaches to obtaining such products are being actively applied in order to reduce the cost of special, expensive tooling of the blanking process. Such technologies include the Direct Metal Deposition (DMD) method, the essence of which is the deposition of metal particles from a gas-powder stream. This method has a lot of advantages, but one of the main drawbacks is that the products after growing have a rough surface and do not meet the accuracy requirements of the finished part drawing. Consequently, the parts require further machining by cutting. However, due to the novelty of the materials, there are no regime parameters for machining. In this regard, the aim of the work is to establish the functional relationship between the cutting force and roughness of the machined surface with the feed per tooth during end milling of EuTroLoy 16604 material formed by DMD-method. In this paper an experimental study of cutting force and roughness of machined surface with varying the tooth feed during end milling is carried out. The research method is an experiment on milling of EuTroLoy 16604 material obtained by DMD-method with measuring the output parameters of the process (cutting force and roughness of the machined surface). Results and discussion. The measured values of cutting force and roughness of the machined surface allowed establishing functional and graphical dependences of the output parameters of the milling process on the feed per tooth. It is found that using a cutter with a smaller clearance angle results in lower cutting forces and the surface has a lower height of microroughness. Thus, the developed functional relationships of cutting force and roughness of the machined surface with the feed per tooth allow predicting the output parameters of the cutting process and increasing the efficiency of machining operations by cutting. A promising direction for further work is seen in the study of relative machinability and evaluation of its quantitative value. For citation: Dyuryagin A.A., Ardashev D.V. A study of the relationship between cutting force and machined surface roughness with the feed per tooth when milling EuTroLoy 16604 material produced by the DMD method. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2022, vol. 24, no. 4, pp. 6–17. DOI: 10.17212/1994-6309-2022-24.4-6-17. (In Russian). ______ * Corresponding author Dyuryagin Alexander A., Post-graduate student South Ural State University, 76 Prospekt Lenina, 454080, Chelyabinsk, Russian Federation Tel.: 8 (351) 272-32-94, e-mail: s.dyuryagin@mail.ru
OBRABOTKAMETALLOV technology Vol. 24 No. 4 2022 DMD increases material utilization because the final product is manufactured by adding the desired amount of material rather than removing it from a solid workpiece; local deposition of material is possible. This method is widely used for coating and the restoration of worn surfaces with powders [4–6]. However, DMD is associated with producing surfaces that do not fully meet the functional requirements [7–10]. Thus, subsequent machining is required. Since DMD is not used in mass production, there are no references for cutting modes for its processing. Most companies machine grown items, selecting suitable cutting modes and cutting tools by trial and error. However, such processing is not effective due to material consumption. Theoretical and experimental testing is required to establish the relationship between the operating parameters and output parameters of the cut. Research data enables the development of a base of recommendations for assigning rational modes of machining DMD-materials. A large number of studies report the characteristics of machining new materials [11-13] and show that the mechanical engineering industry is interested in these materials for the production of parts with the necessary properties. An experimental study of the machinability of Al/SiC-MMC was conducted in [14]. The influence of cutting depth, feed, and cutting speed on the roughness of the machined surface and the cutting force were analyzed. The data established the relationships between these factors, and showed its influence on cutting tool wear. The results enable the selection of suitable values for the feed, cutting speed, and the depth of cut to meet the functional requirements. Eun-Jung Kim et al. [10] conducted an experimental study on the machining of 304L stainless steel. Numerical values of the cutting force and surface roughness were determined to establish the machinability of the material. An experimental model of the relationship between machined surface roughness and cutting modes (spindle speed and feed rate) in turning DMD-produced VT6 titanium alloy was developed in [15]. The milling of IN718 material samples produced using additive technologies are presented in [16–18]. Thus, cutting force, cutting tool wear, surface roughness, and residual stresses under different technological conditions were analyzed. Machinability and the machining process of deposited materials were studied to form a regulatory base for cutting modes. Such data will improve the efficiency of machining operations, which is relevant to the mechanical engineering industry. The purpose of this study is to identify the functional relationship between the cutting force and machined-surface roughness and the feed per tooth during the end milling of DMD-produced EuTroLoy 16604 to improve the efficiency of machining operations. In the furtherance of this goal two steps were taken. - an experimental study of the machinability of milling EuTroLoy 16604 by end mills at different cutting angles, measuring the cutting force and the roughness of the machined surface, was conducted. - mathematical models of the relationship between cutting force and machined surface roughness and feed per tooth were constructed. Research Methodology The sample for the study is a layer of EuTroLoy 16604 powder deposited on a steel plate using DMD (Fig. 1). The layer was deposited in the research laboratory of mechanics, laser processes, and digital production technologies at the South Ural State University using the FL-Clad-R-4 laser cladding complex [19]. The substrate is a plate of structural fine carbon Steel 45 (0.45% C). Deposition modes: laser power – 1,600 W; laser scanning speed – 10 mm/s; powder flow rate – 10.5 g/min; scan step – 1.4 mm. The chemical composition and the size of the powder main fraction are given in Table 1. Amicrostructural examination of the deposited layer was performed using a JEOL JSM 7001-F scanning electron microscope with an X-Max-80 Oxford Instruments X-ray fluorescence energy dispersive analyzer. Thee indentations of the sample were made to measure the microhardness in the depth of the deposited layer using a HV-1000 microhardness tester.
OBRABOTKAMETALLOV Vol. 24 No. 4 2022 technology Fig. 1. A sample of deposited material Ta b l e 1 Chemical composition and the size of the powder main fraction Chemical element The powder main fraction size, µm Fe Co Cr Mo Concentration, at. % 68 15 15 2 40 – 120 The machining was out on a CNC milling machine model GF2171S5. For milling the sample, end mills with a diameter of 8 mm made of R6M5 (HSS-G) material were used. The cutters with 13º and 19º clearance angles in the end section were used to compare the output parameters of the cutting process. Structurally, in most cases, end mills are made with clearance angles, the value of which varies from 13º to 19º. The boundary values of the angles were selected for the experimental study. Guided by the regulatory reference book for the processing of stainless steels [20], the corresponding technological parameters of the milling process were selected. The technological parameters of the experiment, including the characteristics of the cutting tool, are presented in Table 2. To measure the cutting force, a Kistler 9257B dynamometer was used, on which a plate with a deposited material was installed and fixed with screws. The processing of experimental data was carried out using DynoWare software. The machined surface roughness was measured by a contact profilometer model 130 with an accuracy degree 1 according to GOST 19300 – 86. Single-factor regression analysis was used to develop mathematical models of the relationship between the machined surface roughness and the cutting force with the feed per tooth. Ta b l e 2 Technological parameters Feed per tooth Sz, mm/tooth Spindle speed n, rpm Cutting depth t, mm Cutting tool diameter D, mm Cutting tool material 0.01 1,000 0.5 8 HSS M2 0.02 0.03 0.04
OBRABOTKAMETALLOV technology Vol. 24 No. 4 2022 Fig. 2. Thickness of the deposited layer Fig. 3. Microhardness of the deposited layer Results and discussion Properties of the deposited layer The thickness of the deposited layer was determined using a JEOL JSM 7001-F scanning electron microscope and an X-Max-80 Oxford Instruments X-ray fluorescence energy dispersive analyzer (Figure 2). Thickness of the deposited layer varies from 1.36 mm to 1.51 mm and a homogeneous structure with insignificant nonmetallic inclusions in the substrate is observed. The homogeneity of the deposited layer is proven by changes in the microhardness at different depths. The results of microhardness measurements are provided in Figure 3. Cutting force component The operating values of the cutting force were recorded with a signal frequency of 0.1 second. The data were converted in DynoWare and the array of the numerical values of the cutting force was processed in MS Excel. Graphs of the cutting force component Fyz were drawn using built-in functions.
OBRABOTKAMETALLOV Vol. 24 No. 4 2022 technology Figures 4–7 show graphs of the cutting force component Fyz for feeds (Sz) of 0.01 – 0.04, respectively, used in the bending analysis of the cutter. Fyz was calculated from the Fy and Fz components. Cutting was done perpendicular to the laser scanning direction to determine the maximum values of the cutting force arising from blows, i.e., the most unfavorable conditions were chosen for the study. As a consequence, peaks and valleys in the cutting force values are observed in the graphs. The cutting force peaks are in the middle of the weld bead, and the valleys correspond to the positions between the weld beads. To avoid differences in the cutting force results and to give a homogeneous change, machining should be done in the scanning direction. The graphs also show that an increase in the feed leads to an increase in cutting force. Similar results were obtained in [21]. A regression analysis was performed to establish the functional dependence of the cutting force component and the feed per tooth. For this purpose, the five maximum values were selected for each feed. The values of the cutting force component are presented in Table 3. Fig. 4. Graphs of the cutting force component (Sz = 0.01 mm/tooth) Fig. 5. Graphs of the cutting force component (Sz = 0.02 mm/tooth)
OBRABOTKAMETALLOV technology Vol. 24 No. 4 2022 Ta b l e 3 Maximum values of the cutting force component Cutting tool with a 13º clearance angle Feed per tooth Sz, mm/tooth Cutting force component Fyz, N Point No. 1 2 3 4 5 0.01 113.06 111.27 104.05 107.25 104.55 0.02 153 144.75 154.15 157.56 145.94 0.03 194.89 176.16 174.54 184.99 174.6 0.04 315.98 302.59 269.06 289.36 270.28 Cutting tool with a 19º clearance angle Feed per tooth Sz, mm/tooth Cutting force component Fyz, N Point No. 1 2 3 4 5 0.01 117.13 119.47 112.35 113.37 113.29 0.02 193.84 196.16 181.03 172.08 172.18 0.03 325.85 348.92 353.08 309.75 309.92 0.04 423.67 471.75 437.13 428.62 427.28 Fig. 6. Graphs of the cutting force component (Sz = 0.03 mm/tooth) Fig. 7. Graphs of the cutting force component (Sz = 0.04 mm/tooth)
OBRABOTKAMETALLOV Vol. 24 No. 4 2022 technology Fig. 8. Dependences of the cutting force component Fyz on the feed per tooth Sz The results of regression analysis provided us with graphical dependences (Fig. 8) and power functional dependences of the cutting force component Fyz on the feed per tooth Sz for the tool with clearance angles of 13º and 19º, respectively: = 0.65 2037.49 yz z F S , (1) = 0.98 9820.20 yz z F S . (2) Machined surface roughness Measurements of the machined surface roughness were made five times for each feed; the results are presented in Table 4. From the data, it can be seen that an increase in the feed per tooth leads to an increase in roughness. The machined surface roughness is higher at small feeds for the tool with a large clearance angle. To establish the dependence of the machined surface roughness on the tooth feed, a regression analysis was carried out, which made it possible to obtained graphic (Fig. 9) and power functional dependences of the machined surface roughness Ra on the feed Sz for the tool with clearance angles of 13º and 19º, respectively: = 1.019 93.94 z Ra S , (3) = 0.75 41.85 z Ra S . (4) The use of the dependencies enables to predict the output parameters of the machining process when varying the feed per tooth. Conclusions The obtainedmathematical models of the relationship between the cutting force (1), (2) and the roughness of the machined surface (3), (4) with the feed per tooth have the form of power-law dependence. The use of these models enables to predict the machined surface roughness and the cutting force while cutting the DMD-produced material under the given conditions.
OBRABOTKAMETALLOV technology Vol. 24 No. 4 2022 Ta b l e 4 Roughness of the machined surface Cutting tool with a 13º clearance angle Feed per tooth Sz, mm/tooth Roughness of the machined surface Ra, µm Point No. 1 2 3 4 5 0.01 0.91 0.92 0.89 0.98 0.89 0.02 1.58 1.44 1.76 1.53 1.79 0.03 2.42 2.35 2.42 2.23 2.32 0.04 4.01 3.98 4.11 4.13 3.94 Cutting tool with a 19º clearance angle Feed per tooth Sz, mm/tooth Roughness of the machined surface Ra, µm Point No. 1 2 3 4 5 0.01 1.44 1.43 1.45 1.46 1.40 0.02 1.75 1.78 1.74 1.80 1.74 0.03 3.11 3.33 3.12 3.14 3.21 0.04 3.93 4.11 3.85 3.95 3.81 Fig. 9. Dependences of the machined surface roughness Ra on the feed per tooth Sz The measured cutting forces allowed to establish that the maximum values of cutting force range from 113.16 to 315.98 N and from 119.47 to 471.75 N for cutting with clearance angles of 13° and 19° when changing feed from 0.01 to 0.04 mm/tooth respectively; machined surface roughness ranges from 0.89 to 4.13 μm and from 1.4 to 4.11 μm for the first and second tool respectively. At low feed rates, there is a noticeable difference in the machined surface roughness; hence, it can be assumed that cutters with a smaller clearance angle should be used at the finishing stage of machining. Further research on different factors of the cutting process is planned. The base formed as a result of this and future studies will allow the rational assignment of cutting modes in the machining of deposited materials, which will increase the efficiency of technological operation design. The design of mechanical operations takes into account such basic criteria of machining quality as accuracy, which is influenced by cutting force, and roughness. As a consequence, it is necessary to build up a theoretical base on machinability of DMD-produced materials.
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