Vol. 25 No. 3 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.
OBRABOTKAMETALLOV Vol. 25 No. 3 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 Aff airs, 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. Korotkov, D.Sc. (Engineering), Professor, Kuzbass State Technical University, Kemerovo; 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. 3 2023 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Salikhyanov D.R., Michurov N.S. Simulation of the rolling process of a laminated composite AMg3/ D16/AMg3.......................................................................................................................................................... 6 Ilinykh A.S., Pikalov A.S., Miloradovich V.K., Galay M.S. Experimental studies of high-speed grinding rails modes.......................................................................................................................................................... 19 Salikhyanov D.R., Michurov N.S. The concept of microsimulation of processes of joining dissimilar materials by plastic deformation......................................................................................................................... 36 EQUIPMENT. INSTRUMENTS Tratiya D.K., Sheladiya M.V., Acharya G.D., Acharya S.G. Economical crankshaft design through topology analysis for C type gap frame power press SNX-320.......................................................................... 50 Skeeba V.Yu., Vakhrushev N.V., Titova K.A., Chernikov A.D. Rationalization of modes of HFC hardening of working surfaces of a plug in the conditions of hybrid processing................................................................ 63 MATERIAL SCIENCE Ruktuev A.A., Yurgin A.B., Shikalov V.S., Ukhina A.V., Chakin I.K., Domarov E.V., Dovzhenko G.D. Structure and properties of HEA-based coating reinforced with CrB particles.................................................. 87 Maytakov A.L., Grachev A.V., Popov A.M., Li S.R., Vetrova N.T., Plotnikov K.B. Study of energy dissipation and rigidity of welded joints obtained by pressure butt welding................................................... 104 Singh S.P., Hirwani C.K. Analysis of mechanical behavior and free vibration characteristics of treated Saccharum munja fi ber polymer composite...................................................................................................... 117 Pribytkov G.A., Baranovskiy A.V., Korzhova V.V., Firsina I.A., Krivopalov V.P. Synthesis of Ti–Fe intermetallic compounds from elemental powders mixtures.............................................................................. 126 Singh S.P., Hirwani C.K. Free vibration and mechanical behavior of treated woven jute polymer composite............................................................................................................................................................ 137 EDITORIALMATERIALS 152 FOUNDERS MATERIALS 163 CONTENTS
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 5 3 Economical crankshaft design through topology analysis for C type gap frame power press SNX-320 Darshan Tratiya 1, a, *, Manojkumar Sheladiya 1, b, Ghanshyam Acharya 1, c, Shailee Acharya 2, d 1 Atmiya University, Yogidham Gurukul, Kalawad Road, Rajkot, 360005, India 2 Sardar Vallabhbhai Patel Institute of Technology, Affiliated to GTU, Vasad, 388306, India a https://orcid.org/0000-0002-0573-6880, tratiyadarshan@gmail.com, b https://orcid.org/0000-0002-9154-3355, mvsheladiya@gmail.com, c https://orcid.org/0000-0002-3580-3116, ghanshyam.acharya@atmiyauni.ac.in, d https://orcid.org/0000-0001-6428-8961, shailee.acharya@gmail.com 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. 3 pp. 50–62 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2023-25.3-50-62 ART I CLE I NFO Article history: Received: 31 May 2023 Revised: 06 June 2023 Accepted: 07 July 2023 Available online: 15 September 2023 Keywords: Crankshaft structural analysis Computer-aided design Finite element analysis Topology analysis Acknowledgements The group of authors is highly obliged to Mr. Ajit Singh Chawla, Managing Director, Singhal power presses Pct. ltd., Rajkot, Gujarat, India for providing support and facilities for the research work and Mr. Shivang Jani, Asst. Prof. Department of Mechanical Engineering, Atmiya University, Rajkot, Gujarat, India for necessary guidance. ABSTRACT Introduction. The presses are powered machines having stationary beds and slides (rams) which have controlled sliding motion towards and away from the beds, guided by the frames. Metal can be worked in power press in a wide verity of ways like punching, shearing, forming, etc. Crankshaft is one of the basic components for power transmission, which transmits rotary motion to sliding motion in the mechanical power press. It is around this element that all stresses and deformations are concentrated. The purpose of the study: rationalization of the design of the crankshaft, taking into account the strength characteristics of the frame, connection screws, tie rods. The methods include two stages of crankshaft design development: 1) modelling in parametric cad software; 2) FE analysis in Ansys-22R1. The existing as well as the improved design of the crankshaft was investigated by the FE method with topology analysis. Topology is part of FE analysis as well as Generative design. Result and Discussion. The design of the crankshaft, including the bearing assembly, depends largely on the maximum pressure that will be generated at the bottom of the stroke, and this is carefully considered when designing other parts of the presses. Based on the results of the topology analysis of the crankshaft structure, it was found that an increase in the strength of this structural element is possible by adding additional material in the area of potential destruction. During the study, it was possible to develop a rational design of the crankshaft with improved mechanical properties compared to the existing one, which will increase the service life of the crankshaft, preventing its failure. For citation: Tratiya D.K., Sheladiya M.V., Acharya G.D., Acharya S.G. Economical crankshaft design through topology analysis for C type gap frame power press SNX-320. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2023, vol. 25, no. 3, pp. 50–62. DOI: 10.17212/1994-6309-2023-25.3-50-62. (In Russian). ______ * Corresponding author Tratiya Darshan K., Ph.D. (Engineering), Research Scientist Atmiya University, Yogidham Gurukul, Kalawad Road, 360005, Rajkot, Gujarat, India. Tel.: +91-9974364458, e-mail: tratiyadarshan@gmail.com Introduction The presses are powered machines having stationary beds and slides (rams) which have controlled sliding motion towards and away from the beds, guided by the frames. Metal can be processed in a variety of ways with the help of mechanical presses. There are usually several methods of performing any operations that might be required for given piece [1–4]. Presses have long been used in almost all areas of activity
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 5 No. 3 2023 related to the processing of various materials in a cold or hot state: pressing, crushing, shaping, coating, expanding. In any case, due to the technological properties of metals and its wide range, a wide range of technological operations can be applied to it [4]. Stroke length of the power press depends on the eccentricity of crankshaft. Fig. 1 shows the complete nomenclature of the power press [1]. Fig. 1. Press machine arrangement It is used for fast, accurate and economical production of a large number of products by cold working mild steel and other ductile materials. Presses are classified according to the numbers of actions (single, double, triple action etc.), die operation direction (vertical, horizontal, oblique, etc), the kind of power used to operate the dies (mechanical or hydraulic), and mechanism used to drive the dies (crank, knuckle, friction, screw, link, etc [2]. The crankshaft may be called the heart of the press. It is around this member that all stresses and strains are concentrated. The strength of the frame, connecting rod, tie rods and other vital parts are based on the capacity of the crankshaft. The design of the crankshaft, including the location of the bearings, is largely dependent on the maximum pressure that can be generated at the bottom of the stroke, as shown in fig. 2. Standard crankshafts are made of carbon, chromium-manganese, chromium-nickel-molybdenum and other steels, as well as special highstrength cast irons. After stamping, before machining, the shaft blanks are subjected to heat treatment. For a heavily loaded shaft, the following maintenance modes are usually used: normalization, hardening + high tempering (improvement). Fig. 2. Crankshaft layout
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 5 3 The tensile strength and elastic limit of the shaft in some cases can be considerably increased by a special heat-treating process. Special grades of steel having a greater elastic limit than standard shafts can also be used. However, heat treating or special steels are not necessary in most cases. Whenever used, it must be with the greatest caution as heat treating or special steels frequently bring the strength of the crankshaft above that of the other parts. Research methodology All studies of the crankshaft design were divided into two stages of development of this structural element: 1) 3D-modelling using computer-aided design systems; 2) analysis by the finite element method in the Ansys-22R1 software. The existing as well as the improved design of the crankshaft was investigated by the Finite Element Method (FEM) with topology analysis. Topology is part of the Finite Element Analysis (FEA) as well as Generative Design, i.e. technology in which 3D models are created and optimized using cloud computing and artificial intelligence [2–14]. Any physical phenomenon such as the behaviour of structures or fluids, heat transfer, wave propagation, the formation of biological cells, etc. should be fully understood and quantified through mathematics. Partial differential equations (PDEs) are often used to describe most of these processes. However, over the past few decades, numerical methods have been developed to allow a computer to solve these PDEs. One of the best known numerical approaches is FEA. FEM is a numerical method used in FEA that simulates any given physical state. Engineers use FEA software to accelerate the development of better products while reducing costs by minimizing the need for physical models and field experiments, and optimizing components during the design process. Results and Discussion Finite element analysis of existing crankshaft using Ansys22R1 According to the precise 2D drawing, an objective 3D parametric geometry of the crankshaft of a mechanical power press was created using a CAD (computer-aided design) system, such as the Pro/Engineer software package. This solid geometry has been imported in .STEP format for use in structural modelling of an existing project. Currently Singhal Power Presses Pvt. Ltd. collects data on the design of the crankshaft of a mechanical press in this format. To create the model shown in fig. 3, Creo-5.2 was used, which allows creating files according to the .STEP standard [15–18]. The highlighted region in fig. 4 shows the results of the overall deformation after applying a force of 320 tons to the centre of the crankshaft. The maximum deformation occurs in the middle of the crankshaft, where a load of 320 tons acts and the deformation value is 0.050 mm, while the deflection in the bearing area is practically 0 mm. Fig. 5 shows the equivalent stress in the corners near the crankshaft web under a load of 320 tons with a maximum value of 162.05 MPa and a minimum value of 9.64 MPa in the bearing area. Fig. 3. Existing design of crankshaft
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 5 No. 3 2023 From fig. 6, it is obvious that when a load of 320 tons is applied, the crankshaft experiences the greatest tension, while the maximum shear stress is 93.008 MPa, and the minimum shear stress is 0.106 MPa. The crankshaft bearing area experiences maximum stress when a load of 320 tons is applied (fig. 7). The maximum principal stress here is 132.01 MPa and the minimum principal stress is -58.67 MPa, causing negative stresses on the end face (table 1). Fig. 4. Total deformation of existing crankshaft Fig. 5. Equivalent stress of existing crankshaft Fig. 6. Maximum shear stress in existing crank shaft
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 5 3 Fig. 7. Maximum principal stress in existing crankshaft Ta b l e 1 Structural analysis results of existing crankshaft Total Displacement, mm Von-Mises Stress Theory, MPa Max Principal Stress, MPa Max. Shear Stress, MPa 0.050 162.05 132.01 93.00 Finite element analysis of optimized crankshaft using Ansys22R1 It is obvious that almost every component of the kinematic chain in the assembly, for which topological optimization has not been carried out, is overweight. The additional weight of structural elements leads to the use of excess material, which is the reason for the formation of excessive loads on moving components, reducing energy efficiency and increasing transportation costs [19–25]. And thanks to Topological Optimization technology (ANSYS Mechanical), there is a tool one needs to design strong and lightweight structural elements, regardless of its application. Targets can be easily defined and controls applied to ensure that manufacturing requirements are met, minimum material thicknesses are set, and exclusion areas are defined [26–29]. Topology optimization in ANSYS Mechanical allows: 1) taking into account multiple static loads in combination with optimization of natural frequencies (modal analysis); 2) meeting minimum material thickness requirements; 3) observing the rules regarding the direction of basing (installation) of the element (for example, for machining operations); 4) obtaining the possibility of implementing both cyclic and planar symmetry. The highlighted region in fig. 8 shows the results of the total deformation after applying a load of 320 tons to the centre of the crankshaft. The maximum deformation occurs in the middle of the crankshaft, where a load of 320 tons is applied, and the deformation value is 0.046 mm, but the deflection in the bearing area is practically 0 mm. Fig. 9 shows the equivalent stress at the end surfaces of the crankshaft. When applying a load of 320 tons, the crankshaft experiences the highest stresses on the end surfaces with a maximum equivalent stress of 191.24 MPa; in this case, the minimum equivalent stress occurs in the bearing area and is equal to 11.64 MPa.
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 5 No. 3 2023 When a load of 320 tons is applied, the crankshaft bearing area experiences maximum stress (fig. 10). The maximum principal stress at this location is 189 MPa and the minimum principal stress at the end face is -11.27 MPa, causing a negative stress. Fig. 8. Total deformation of optimized crankshaft Fig. 9. Equivalent stress in optimized crankshaft Fig. 10. Maximum principal stress in optimized crankshaft
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 5 3 From fig. 11 it is clear that the maximum stresses occur at the corner of the crankshaft when a load of 320 tons is applied, with the maximum shear stress is 98.124 MPa and the minimum shear stress is 0.2156 MPa. Fig. 11. Maximum shear stress in optimized crankshaft Ta b l e 2 Structural analysis results of optimized crankshaft Total Displacement, mm Von-Mises Stress Theory, MPa Max Principal Stress, MPa Max. Shear Stress, MPa 0.0463 191.34 189 98.124 Ta b l e 3 Comparison of the existing and optimized crankshaft Existing crank shaft New developed crank shaft Percentage wise Improved results Total Displacement 0.050 mm 0.0463 mm 7.45 % Von-Mises Stress Theory 162.05 MPa 191.34 MPa 15.30 % Max Principal Stress 132.01 MPa 189 MPa 30.15 % Max. Shear Stress 93.008 MPa 98.124 MPa 5.21 % Conclusion From the results obtained by the Finite Element Method both for the existing design of the crankshaft and for the optimized one, it can be concluded that the optimization of the design of the crankshaft of a mechanical press leads to an increase in its performance in terms of reducing the bending deviation by 4 µm compared to the previous design. In addition, according to Table 3, the optimized crankshaft design shows improved von Mises results of 15.30 %, maximum principal stress of 30.15 %, and maximum shear stress of -5.21 %. References 1. Montazersadgh F.H., Fatemi A. Dynamic load and stress analysis of a crankshaft. SAE Technical Paper. SAE International, 2007. DOI: 10.4271/2007-01-0258. 2. Shahane V.C., Pawar R.S. Optimization of the crankshaft using finite element analysis approach. Automotive and Engine Technology, 2017, vol. 2 (1–4), pp. 1–23.
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