Vol. 25 No. 1 2023 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. 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 Journal “Obrabotka Metallov – Metal Working and Material Science” is indexed in the world's largest abstracting bibliographic and scientometric databases Web of Science and Scopus. 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. WEB OF SCIENCE
OBRABOTKAMETALLOV Vol. 25 No. 1 2023 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; 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. 25 No. 1 2023 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Ryaboshuk S.V., Kovalev P.V. Analysis of the reasons for the formation of defects in the 12-Cr18-Ni10-Ti steel billets and development of recommendations for its elimination............................................................... 6 Lapshin V.P., Moiseev D.V. Determination of the optimal metal processing mode when analyzing the dynamics of cutting control systems................................................................................................................... 16 Gimadeev M.R., Li A.A., Berkun V.O., Stelmakov V.A. Experimental study of the dynamics of the machining process by ball-end mills.................................................................................................................. 44 Bratan S.M., Chasovitina A.S. Simulation of the relationship between input factors and output indicators of the internal grinding process, considering the mutual vibrations of the tool and the workpiece................... 57 EQUIPMENT. INSTRUMENTS Podgornyj Yu.I., KirillovA.V., Skeeba V.Yu., Martynova T.G., Lobanov D.V., Martyushev N.V. Synthesis of the drive mechanism of the continuous production machine......................................................................... 71 Lobanov D.V., Rafanova O.S. Methodology for criteria analysis of multivariant system................................ 85 MATERIAL SCIENCE Sokolov A.G., Bobylyov E.E., Popov R.A. Diffusion coatings formation features, obtained by complex chemical-thermal treatment on the structural steels............................................................................................ 98 Filippov A.V., Khoroshko E.S., Shamarin N.N., Kolubaev E.A., Tarasov S.Yu. Study of the properties of silicon bronze-based alloys printed using electron beam additive manufacturing technology................... 110 Lysykh S.A., Kornopoltsev V.N., Mishigdorzhiyn U.L., Kharaev Yu.P., Tikhonov A.G., Ivancivsky V.V., Vakhrushev N.V. The effect of borocoppering duration on the composition, microstructure and microhardness of the surface of carbon and alloy steels............................................................................................................. 131 EDITORIALMATERIALS 149 FOUNDERS MATERIALS 159 CONTENTS
OBRABOTKAMETALLOV Vol. 25 No. 1 2023 TECHNOLOGY Experimental study of the dynamics of the machining process by ball-end mills Mikhail Gimadeev a, *, Andrey Li b, Vera Berkun c, Vadim Stelmakov d Pacific National University, 136 Tihookeanskaya St., Khabarovsk, 680035, Russian Federation a https://orcid.org/0000-0001-6685-519X, 009063@pnu.edu.ru, b https://orcid.org/0000-0002-9907-4936, 011864@pnu.edu.ru, c https://orcid.org/0000-0002-5249-2612, 2015103121@pnu.edu.ru, d https://orcid.org/0000-0003-2763-1956, 009062@pnu.edu.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. 2023 vol. 25 no. 1 pp. 44–56 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2023-25.1-44-56 ART I CLE I NFO Article history: Received: 07 November 2022 Revised: 14 January 2023 Accepted: 21 January 2023 Available online: 15 March 2023 Keywords: Ball-end mill Surface roughness Vibration Correlation analysis Regression analysis Online monitoring Tool tilt Funding The study was carried out with the financial support of the Ministry of Education and Science of the Khabarovsk Territory within the framework of the regional competition for grants in the form of subsidies from the regional budget for the implementation of projects in the field of fundamental, technical, humanitarian and social sciences. Grant No. 93C/2022 on the topic “Improving the efficiency of process equipment during machining through online monitoring of an acoustic signal”. Acknowledgements The authors express gratitude to A.V. Nikitenko, Ph.D. in Engineering Science, Associate Professor of the Department of Technological Informatics and Information Systems (PNU, Khabarovsk), for helping to organize and conduct experimental research at the CAD/CAM technology training and production center. Research were partially conducted at core facility “Structure, mechanical and physical properties of materials”. ABSTRACT Introduction. Due to a significant number of factors affecting the change in the properties of a dynamic system, excessively conservative processing conditions are chosen to ensure the high quality of the resulting product. This limits the efficiency of the process and leads to an increase in the cost of production. Accordingly, modern approaches are needed that will allow diagnosing the current state of processing and making timely decisions to replace the tool, correct or change the control program. The significance of the ongoing research is to propose a real-time monitoring approach to milling control to identify emerging processing errors, predict potential problems and improve uptime. Subject. The paper discusses the features of the real-time monitoring system during mechanical processing with a single- and double-edge cutting tool, taking into account acoustic wave filtering, minimizing surface roughness. The purpose of the work is to determine the effect of the inclination orientation of the ball-end tool on the surface roughness value using real-time monitoring during milling on CNC process equipment. Methods. The study provides methods of correlation and regression analysis. The calculated data were obtained by means of vibroacoustic diagnostics and measured in the range of values of the variable angle of inclination of the surface for single- and double-edge cutting tool based on the provisions of the theory of oscillations and vibroacoustic diagnostics, cutting theory, digital processing and digital filtering of signals. Results and discussions. Experimental data obtained during machining made it possible to determine that an increase in the angle of inclination of a single-edge cutting tool has practically no effect on the change in the amplitude parameters of roughness. The values of vibroacoustic diagnostics and roughness, when using a double-edge ball-end tool, show a consistent picture with the effects created by the angles of inclination and advance. The obtained solutions to the problems of monitoring and analyzing the roughness parameters can significantly reduce the amount of experimental research and clarify the idea of the practical implementation of the method of acoustic monitoring of the cutting process. For citation: Gimadeev M.R., Li A.A., Berkun V.O., Stelmakov V.A. Experimental study of the dynamics of the machining process by ball-end mills. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2023, vol. 25, no. 1, pp. 44–56. DOI:10.17212/1994-6309-2023-25.1-44-56. (In Russian). ______ * Corresponding author Gimadeev Mikhail R., Ph.D. (Engineering), Associate Professor Pacific National University, 136 Tihookeanskaya St., Khabarovsk, 680035, Russian Federation Тел.: 8 (924) 216-31-39, e-mail: 009063@pnu.edu.ru
OBRABOTKAMETALLOV technology Vol. 25 No. 1 2023 Introduction One of the main directions in the development of machine-building production is to increase the reliability of mechanical processing of spatially complex surfaces by using a real-time monitoring system designed to obtain reliable information on the state of the milling process and make the necessary control decisions [1–6]. To solve the problems of controlling the milling process, many authors study the change in the active contact zone of the end milling tool and the workpiece. Pimenov D. et al. [7] presented practical recommendations for assigning the orientation of the tool to the workpiece, taking into account the milling dynamics to ensure surface roughness. Tan L. et al. [8] studied the effect of tool path contours on ball-end tool wear and surface roughness during milling. The results showed that the use of the bottom-up tool path contour makes it possible to ensure the minimum amplitude parameters of roughness, and the prevailing type of tool wear is adhesive. Issues related to monitoring the state of technological equipment at industrial enterprises are considered in the works of scientists Kozochkin M.P., Sabirov F.S. [9]. In the work of Shaffer D. et al., acoustic signals were investigated as a way to control the operation of technological equipment [10]. Experimentally with different cutting conditions, mathematical models were statistically determined showing the change in acoustic signal for end milling with a single cutting edge. Kozlov A.A., AL-Jonid Khalid, in their study determined the basic requirements for diagnosing and predicting the wear of a cutting tool in real time [11]. Chen et al. proposed a real-time monitoring system [6] with error compensation to improve accuracy in the production of spatially complex parts [12]. Cheng DJ. et al. [13] studied the effect of cutting parameters on the roughness of the machined surface [6]. Clayton Cooper [14], Anayet U Patwari et al. [15] analyzed the correlation of surface roughness parameters with the sound level based on the acoustic signal. Authors Sahinoglu A. and Rafighi M. [16] investigated the effect of cutting parameters on surface roughness, vibration, sound intensity of technological equipment during machining. Many authors have proposed ways to ensure the output characteristics of processing by controlling the elastic deformations of the tool relative to the workpiece, taking into account the state of the dynamic system (DS) [17–20]. The analysis of scientific works made it possible to formulate the direction of this research: to generalize and gain new knowledge, as well as to clarify the applicability of an acoustic complex that registers a signal through the air to control the cutting process, with filtering interference and noise in real time. The purpose of the work is to determine the effect of the inclination orientation of the ball-end tool on the surface roughness value using real-time monitoring during milling on CNC process equipment. At the same time, on the basis of empirical data, it is necessary to develop a model for the dependence of the roughness of the machined surface on the feed rate, diameter and orientation of the tool with the correlation of the obtained values and vibroacoustic diagnostics. Research methodology Machining was carried out in climb milling using a cutting fluid (coolant) on workpieces with Al-Mg6 properties, by hard alloy ball-end mills with a TiN coating with a diameter of D = 8 mm and a number of teeth z = 1, z = 2. The feed per tooth was fz = 0.2 mm/tooth, the allowance for all specimens was ap = 0.4 mm, the lateral pitch ae = 0.2 mm. The overhang ratio of the tool is assumed to be l/D = 4. The rotation frequency (n) of the milling machining center DMG DMU 50 Ecoline was for a double-edge cutting tool 1,500 min–1, for a single-edge cutting tool 3,000 min–1. The use of coolant is an important factor in the intensification of the cutting process, since the hard alloy has a low resistance to tensile stresses [21]. When using coolant, films are formed on the contact surfaces of the tool and workpiece material, which help to reduce adhesive wear. Dimensional wear control of the cutting tool was carried out using a Heidenhain TT140 contact measuring sensor. The accuracy of straightness when measuring the roughness parameters with the Surfcom 1800D instrument was Δ = ± (0.05 + 1.5L / 1,000). Vibroacoustic diagnostics (Fig. 1) was carried out us-
OBRABOTKAMETALLOV Vol. 25 No. 1 2023 technology ing the spectrum analyzer «ZetLab 017–U2», piezoelectric vibration sensors «BC 110», microphone «Zet BC 501» with a perceived frequency range of 20 Hz–13 kHz and Samson Meteor Mic cardioid directivity with a range of 20 Hz–20 kHz. The roughness parameter Rz (μm), vibration displacement S (μm) and the amplitude–frequency characteristic of the acoustic signal A (dB), ω (Hz) were used as the output evaluation of the processing efficiency. The use of a condenser microphone has a number of advantages – low frequency response, low level of non-linear and transient distortion, high sensitivity and low self-noise. Particular attention should be paid to improving the quality of the diagnostic signal, which consists of the sum of the spectrum of the “useful” signal and a large number of unequal noise levels coming from various objects. Spectral subtraction was used for real-time noise reduction. The most common method of denoising is spectral subtraction (Fig. 2). The decomposition of the signal during spectral subtraction was carried out using a special weight function [22] – the Blackman window. Research results In the process of machining, a change in the properties of the DS is observed, which is determined by various factors. The disclosure of the features of the loss of stability of the toolpath during milling (Fig. 3) makes it possible to determine ways to improve the reliability of the operation of technological equipment (TE). Fig. 1. Real-time monitoring in milling: 1 – vibration sensor and microphone with cardioid orientation; 2 – spectrum analyzer «ZetLab 017-U2»; 3 – PC with ZETLAB software (Formulated by the authors) Fig. 2. The proposed spectral subtraction algorithm scheme: x(t) – original signal; STFT – Short Time Fourier Transform; W(f) – is the function of the weighting window; y(t) – transformed signal (Formulated by the authors)
OBRABOTKAMETALLOV technology Vol. 25 No. 1 2023 a b Fig. 3. Pattern of the passage of the cutting edges through the processing zone: a – the trajectory of the ith tooth corresponding to the effective diameter of the tool; b – deviation trajectory of the front spindle support (Formulated by the authors) Ta b l e 1 Roughness parameters after machining with a ball–end tool Number of teeth Angle of inclination, ° Roughness parameters, μm Ra Rq Rz Rt Rp 1 10 0.436 0.543 2.143 4.094 1.490 25 0.498 0.531 2.532 4.810 1.355 40 0.401 0.502 2.512 4.800 1.271 2 10 0.661 0.824 3.048 4.536 2.001 25 0.620 0.793 5.104 7.599 3.079 40 0.373 0.465 2.391 3.559 1.383 In this study, the output parameter is roughness, and to ensure the required surface roughness, along with the establishment of processing modes, an assessment is made of the dynamics of spatial oscillations of the front spindle support (see Fig. 3, b). At the same time, the amplitude parameters of roughness after processing with inclined ball-end tools with a different number of teeth during climb milling are presented in Table 1. When machining with a single-edge cutting tool, a change in the angle of inclination practically does not affect the change in the amplitude parameters of roughness, i.e. for the case under consideration, the range of the DS stability margin is maximum. The use of a double-edge cutting tool leads to significant changes in the output parameters, the discrepancies presented are often caused by the deviation and wear of the tool, resulting in a change in the active cutting zone and an increase in the level of vibrations [6] (Fig. 4). Analysis of the Table 1 as well as Fig. 4 allows drawing the following conclusions: 1) the greater the vibration displacement amplitude, corresponding to the cutting frequency, the higher the value of the roughness amplitude parameters; 2) the amplitude of vibration displacements does not change linearly with an increase in the angle of inclination, and a decrease in the quality of the machined surface occurs due to elastic deformations of the cutting tool, which is explained by the distribution of the cutting force components along the cutting edge [20, 23]. For the practical implementation of the principles of acoustic diagnostics, the information received on the current state of the processing process is required to be understandable and reliable. Fig. 5 shows the acoustic signal obtained during the experiment.
OBRABOTKAMETALLOV Vol. 25 No. 1 2023 technology Fig. 4. Comparison of the frequency spectrum after milling with different angles of inclination, z = 2 (Formulated by the authors) a b c Fig. 5. Frequency spectrum of the acoustic signal: a – spindle acceleration to 8,000 min–1 and stop; b – machining process, z = 1, n = 3,000 min–1; c – machining process, z = 2, n = 1,500 min–1 (Formulated by the authors)
OBRABOTKAMETALLOV TECHNOLOGY Vol. 25 No. 1 2023 Fig. 6. Frequency response of harmonic sound waves obtained by milling with an inclination angle of 40° (Formulated by the authors) Fig. 7. Filtered acoustic signal (Formulated by the authors) The frequency spectra considered in Fig. 5 in a detailed analysis, are consistent with the vibration diagnostics signals, however, it is advisable to analyze the acoustic signal within the cutting frequency range. To extract a narrow band of the sound wave (Fig. 6), FFT filter was used, which used a fast Fourier transform (FFT), the FFT size corresponded to a value of 4,096. The frequency ω1 corresponds to the cutting frequency (see Fig. 6), and according to the harmonic law, the resonant frequencies are found as the product of ω1 and an integer (ω1 = 50 Hz, 2ω1 = 100 Hz, etc.). The frequencies are calculated up to the fourth order, since with an increase in the order the intensity of the mode frequency decreases markedly and at higher orders it has practically no effect on the overall sound picture. It can be seen from the records (Fig. 7) that the acoustic signal is modulated by the tool revolutions, and when cutting with a double-edge cutting tool, the signal amplitude changes when the tool inclination angle changes. When studying the spectrum of acoustic diagnostic signals, a uniform phase alternation and the absence of a chaotic regime are established. After denoising, filtering and normalizing the signal amplitude, a limited number of bifurcation points are determined when the tool inclination angle is changed during machining. These facts allow concluding that the method of acoustic monitoring has informative diagnostic features.
OBRABOTKAMETALLOV Vol. 25 No. 1 2023 technology Given the increasing demands on the quality of parts, it is worth focusing on the predictability of roughness parameters during machining, in this study – through correlation. Identified dependencies based on the value of the pair correlation coefficient in Table 2 indicate the possibility of influencing some of the obtained parameters through changing others and the presence of technological parameters predetermining the micro-roughness of the surface. Ta b l e 2 Calculated values of the pair correlation coefficients Compared values Correlation coefficient The existence of a linear relationship Linear connection Ф1 (Ra) R (Rz) 0.91 highly probable increases Ф2 (Rq) R (Rz) 0.92 highly probable increases Ф3 (Rt) R (Rz) 0.98 highly probable increases Ф4 (Rp) R (Rz) 0.93 highly probable increases Ф5 (γ) R (Rz) –0.41 very improbable decreases Ф6 (z) R (Rz) 0.40 very improbable increases Ф5 (γ) Ф6 (z) 0.00 doesn’t exist – Noted in theTable 2 correlations are significant at p < 0.05. It is generally accepted that a linear dependence exists if the modulus of the correlation coefficient corresponds to a value from 0.5 to 1. However, the value of the coefficient in the range of 0.3...0.5 may indicate the existence of a non-linear correlation [24, 25]. The regression graph of the parameter Rz (Fig. 8) indicates the confirmation of the above position. To assess the degree of influence of the angle of inclination on the amplitude parameter of roughness Rz, a multivariate regression analysis is carried out. The result of the analysis is a mathematical model (1), which characterizes the relationship between the value of roughness, feed per tooth, diameter and angle of inclination of the tool, expressed by the normalized model the graphical interpretation of which is shown in Fig. 9. 3 2.77 0.55 1.08 0.51 1 0.22 0 . .2 z z z z z f y D f f D D f D R γ γ γ = + − + − − + − (1) Fig. 8. Parameter Rz depending on the machining angle for a double-tooth cutter (Formulated by the author)
OBRABOTKAMETALLOV technology Vol. 25 No. 1 2023 a b Fig. 9. Dependences of the roughness Rz on the feed and the angle of inclination of the tool: a – theoretical; b – experimental With a confidence coefficient P = 0.95, the calculated value of the Fisher criterion Fcalc is less than the tabular value Ftabl, respectively, the hypothesis of an adequate representation of the regression model (1) is accepted. The analysis of theoretical and experimental data on the relationship between the parameters of roughness, feed per tooth and the angle of inclination shown in Fig. 9 indicates minor differences in data presentation. At the same time, the shape of the experimental dependence differs from the theoretically calculated one by equation (1) by no more than 10 %. Conclusions Experimental data obtained during machining made it possible to determine that an increase in the angle of inclination of a single-edge cutting tool has practically no effect on the change in the amplitude parameters of roughness. The values of VA diagnostics and roughness when using a double-edge ball-end tool show a consistent picture with the effects created by the angles of inclination and advance. At the same time, at a cutting frequency of 50 Hz, the vibration displacement magnitude for an angle of inclination 25° is, on average, 2 times greater than at 10° and 40°. Roughness amplitude parameters Ra, Rq, Rt, Rp show a high degree of correlation with the Rz parameter. Due to the non-linear relationship between the Rz value, feed fz, tool inclination angle γ and tool diameter D, a regression model is developed that allows predicting the roughness of the machined surface. The obtained solutions to the problems of monitoring and analyzing the roughness parameters can significantly reduce the amount of experimental research and clarify the idea of the practical implementation of the acoustic method for controlling the cutting process in real time. References 1. Anstev A.V., Ngon D.T., Trong D.H., Yanov E.S. Influence of vibration amplitude on tool wear during ball end milling of hardened steel. 2018 4th International Conference on Green Technology and Sustainable Development. IEEE, 2018, pp. 232–236. DOI: 10.1109/GTSD.2018.8595567.
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