Adaptation of the CNC system of the machine to the conditions of combined processing

Vol. 26 No. 1 2024 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. 26 No. 1 2024 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, V.P. Larionov Institute of the Physical-Technical Problems of the North of the Siberian Branch of the RAS, Yakutsk; Alexander S. Yanyushkin, D.Sc. (Engineering), Professor, I.N. Ulianov Chuvash State University, Cheboksary

Vol. 26 No. 1 2024 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Kuts V.V., Oleshitsky A.V., Grechukhin A.N., Grigorov I.Y. Investigation of changes in geometrical parameters of GMAW surfaced specimens under the infl uence of longitudinal magnetic fi eld on electric arc....................................... 6 Saprykina N.А., Chebodaeva V.V., Saprykin A.А., Sharkeev Y.P., Ibragimov E.А., Guseva T.S. Optimization of selective laser melting modes of powder composition of the AlSiMg system................................................................. 22 Gubin D.S., Kisel’ A.G. Features of calculating the cutting temperature during high-speed milling of aluminum alloys without the use of cutting fl uid............................................................................................................................................. 38 EQUIPMENT. INSTRUMENTS Borisov M.A., Lobanov D.V., Zvorygin A.S., Skeeba V.Y. Adaptation of the CNC system of the machine to the conditions of combined processing...................................................................................................................................... 55 Nosenko V.A., Bagaiskov Y.S., Mirocedi A.E., GorbunovA.S. Elastic hones for polishing tooth profi les of heat-treated spur wheels for special applications..................................................................................................................................... 66 Podgornyj Y.I., Skeeba V.Y., Martynova T.G., Lobanov D.V., Martyushev N.V., Papko S.S., Rozhnov E.E., Yulusov I.S. Synthesis of the heddle drive mechanism....................................................................................................... 80 MATERIAL SCIENCE Ragazin A.A., Aryshenskii V.Y., Konovalov S.V., Aryshenskii E.V., Bakhtegareev I.D. Study of the eff ect of hafnium and erbium content on the formation of microstructure in aluminium alloy 1590 cast into a copper chill mold............................................................................................................................................................................ 99 Zorin I.A., Aryshenskii E.V., Drits A.M., Konovalov S.V. Study of evolution of microstructure and mechanical properties in aluminum alloy 1570 with the addition of 0.5 % hafnium........................................................................... 113 Karlina Y.I., Kononenko R.V., Ivantsivsky V.V., Popov M.A., Deryugin F.F., Byankin V.E. Relationship between microstructure and impact toughness of weld metals in pipe high-strength low-alloy steels (research review)..................... 129 Patil N.G., Saraf A.R., Kulkarni A.P Semi empirical modeling of cutting temperature and surface roughness in turning of engineering materials with TiAlN coated carbide tool................................................................................. 155 Sawant D., Bulakh R., Jatti V., Chinchanikar S., Mishra A., Sefene E.M. Investigation on the electrical discharge machining of cryogenic treated beryllium copper (BeCu) alloys........................................................................................ 175 Karlina A.I., Kondratiev V.V., Sysoev I.A., Kolosov A.D., Konstantinova M.V., Guseva E.A. Study of the eff ect of a combined modifi er from silicon production waste on the properties of gray cast iron................................................. 194 EDITORIALMATERIALS 212 FOUNDERS MATERIALS 223 CONTENTS

OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 1 4 Adaptation of the CNC system of the machine to the conditions of combined processing Mikhail Borisov 1, a, Dmitry Lobanov 1, b, *, Alexander Zvorygin 2, c, Vadim Skeeba 3, d 1 I.N. Ulianov Chuvash State University, 15 Moskovsky Prospekt, Cheboksary, 428015, Russian Federation 2 Russian Federal Nuclear Center - All-Russian Research Institute of Experimental Physics, 37 Mira Ave., Sarov, 607188, Russian Federation 3 Novosibirsk State Technical University, 20 Prospekt K. Marksa, Novosibirsk, 630073, Russian Federation a https://orcid.org/0000-0001-9084-1820, borisovmgou@mail.ru; b https://orcid.org/0000-0002-4273-5107, lobanovdv@list.ru; с https://orcid.org/0000-0003-3610-4648, zvor95@yandex.ru; d https://orcid.org/0000-0002-8242-2295, skeeba_vadim@mail.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. 2024 vol. 26 no. 1 pp. 55–65 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2024-26.1-55-65 ART I CLE I NFO Article history: Received: 11 December 2023 Revised: 25 December 2023 Accepted: 08 January 2024 Available online: 15 March 2024 Keywords: CNC machine Electrochemical grinding Programmable device Automatic control Combined processing Control program Funding This research was funded by Russian Science Foundation project N 23-29-00945, https://rscf.ru/en/project/23-29-00945/ Acknowledgements Researches were conducted at core facility of NSTU “Structure, mechanical and physical properties of materials”. ABSTRACT Introduction. Increasing the effi ciency of processing technologies for products made from modern highstrength, diffi cult-to-process materials with increased physical, mechanical and operational properties consists not only in improving the technology itself, the tools for its implementation, but also in modernizing technological equipment taking into account new achievements in the fi eld of mechanical engineering. Modern computer numerical control (CNC) equipment is now quite advanced in terms of controlling basic cutting movements. Adaptive monitoring and control systems, as a rule, additionally installed on processing equipment, make it possible to further improve the quality of processing parameters. With the development of new hybrid and combined technologies that combine several types of infl uence on the product being processed, the issue of synchronizing the automatic control of the movements of parts of technological equipment with the control and management of accompanying processes of combined technologies has become acute. One example of such technologies is electrochemical diamond grinding with periodic dressing of the working surface of a diamond wheel using reverse polarity current. The polarity of the current and the duration of its pulses are controlled by special programmable devices. Current switching units are connected to it. It serves to supply alternating currents of direct and reverse polarity to the electrical circuit and is made on the basis of key elements. Installing such programmable devices on CNC machines leads to its’ equipping with an additional autonomous automatic control system. At the same time, it is diffi cult to coordinate the operation of the machine’s CNC system, which controls the movements of its working parts, and the programmable device used to control the polarity and duration of current pulses during combined processing. The purpose of the work is to synchronize the CNC system of the machine with the control system for the process of periodically changing the polarity of the current. The study was carried out on an experimental stand. Methods. The research methodology involved conducting an experiment consisting of synchronizing the operation of the machine’s CNC system with the operation of the control system for the process of periodically changing the polarity of the current. To evaluate the results, the time of movement of the diamond wheel as a result of the working stroke was compared with the duration of current pulses of diff erent polarities specifi ed in the control program of the developed software. Results and discussions. As a result of the research, it is established that the developed software and hardware complex makes it possible to synchronize in the CNC system of the machine tool the control of the movements of the working parts with automatic control of the periodic change of current polarity during electrochemical diamond grinding, which can signifi cantly expand the technical capabilities of CNC machines. For citation: Borisov M.A., Lobanov D.V., Zvorygin A.S., Skeeba V.Y. Adaptation of the CNC system of the machine to the conditions of combined processing. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2024, vol. 26, no. 1, pp. 55–65. DOI: 10.17212/1994-6309-2024-26.1-55-65. (In Russian). ______ * Corresponding author Lobanov Dmitry V., D.Sc. (Engineering), Professor I.N. Ulianov Chuvash State University, 15 Moskovsky Prospekt, 428015, Cheboksary, Russian Federation Tel.: + 7 908 303-47-45, e-mail: lobanovdv@list.ru

OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 1 2024 Introduction To improve the process effi ciency for items made of modern high-strength, tough-to-machine materials with advanced mechanical and physical properties and performance, it is required both to improve the process itself and the process-related tooling [1–7], and to upgrade the equipment taking into account the new technologies in the fi eld of the mechanical engineering. In this case, the prospective effi ciency improvement can be achieved by process control automation that could reduce considerably the machining and handling time and improve the fi nish quality and productivity. As of today, modern CNC machines are far enough advanced to control the main cutting movements [8–10]. Adaptive control systems that process equipment is usually fi tted with contribute to making the process quality even higher. With advances in new hybrid and mixed technologies [11–20] that combine several types of action on the item to be machined, the issue of timing between the automatic control of process equipment driven elements movement and companion process control of the mixed technologies became critical. One of examples of such technologies is electrochemical diamond grinding with regular dressing of the diamond grinding wheel face by reverse polarity currents [21–24]. To make electrochemical action on the material to be machined possible, an electrical circuit comprising the DC source, the material to be ground and conductive diamond wheel is created. Electrolyte fl uid is fed to the grinding area. For machining, the workpiece is connected with the positive contact of the current source. The surface under machining became softer that contributes to the diamond grinding modes improvement. However, during operation, the effi ciency of the diamond-bearing layer degrades due to fouling. Tool cutting performance restoration is required, and one embodiment is the current source polarity reversing that makes electrochemical dressing of the diamond-bearing layer possible. Thus, to maintain the wheel performance, periodic current pulses are fed to the electrical circuit. Special programmable devices are used to control current polarity and pulse duration [25]. These devices are connected to current switching units. These key element-based units serve to feed direct and reverse polarity currents alternatively to the electrical circuit. CNC machines fi tted with such programmable devices require additional non-interacting automatic control system to be used. In this case, it is challenging to coordinate the driven elements movement control system of the CNC machine and the programmable device that controls current pulses polarity and duration during the mixed processing. In this regard, the purpose is to synchronize the machine’s CNC system and the current polarity switching control system. Methods for studying To investigate the process of automatic control of current polarity during electrochemical grinding and regular dressing of the diamond grinding wheel face using the machine’s CNC system, we used a proprietary test bench. The test bench is based on a three-axis CNC machine, presented in fi g. 1. The machine is equipped with three step motors controlled by the Arduino control board and G codes. For a process sequence programming, a PC SW is used. Fig. 2 shows arduino-based CNC machine control logic. To simulate the mixed processing conditions, the test bench was additionally fi tted with DC circuit comprising the current source, current switching unit, material to be machined, and grinding tool. The spindle was installed horizontally and fi tted with a grinding tool mandrel. The machine components that are the part of the electrical circuit as well as the workpiece holder were insulated by dielectric joints. Overview of the test bench with retrofi ts is shown in fi g. 3. Fig. 1. Three-axis CNC machine

OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 1 4 To control the electrochemical processes during the investigation, the test bench was additionally fi tted with the proprietary current polarity control board and relay block, which were coordinated with the existing step motor control board of the machine. Such confi gured device was housed inside the integrated control unit casing made by additive manufacturing, see in fi g. 4. At the side of the integrated unit, there are “IN” and “OUT” terminal blocks. The purpose of these blocks is to supply DC to the integrated control unit and transmit current pulses of the appropriate polarity to the material to be machined and the grinding wheel. To start the investigation, fi rst, the step motors were calibrated. For this, proximity switches were used. Using these switches, the initial position of the machine slides in the machine’s coordinate system was set for correct execution of the process sequence. The process sequence programmed with the G and M codes is conveyed from the PC memory to the Arduino control board via USB connection. The process sequence controls the machine drives and current polarity of the circuit comprising the current source, current switching unit, conductive grinding tool and the material to be ground. Fig. 2. CNC machine control circuit using Arduino Fig. 3. Experimental stand: 1 – machine table; 2 – connecting terminal; 3 – device for installing the workpiece; 4 – diamond wheel; 5 – brush device; 6 – stepper motor; 7 – integrated control device; 8 – display unit Fig. 4. Integrated control device

OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 1 2024 One of the investigation targets is to time the machine drives and circuit current polarity reversing. Current polarity may be reversed either in sequence during operation at set time intervals (for electrochemical grinding and dressing) or when changing the material to be machined from one to another (soldered joints, sandwich materials). According to the investigation procedure, an experiment should be performed, during which the machine’s CNC system shall be timed with the current polarity switching control system. For the purpose of the results estimation, we compared the time for the diamond wheel movement during the working stroke with the pulse duration of various current polarities set by the process sequence of developed SW. Results and its discussion During the investigation, we developed the shared control logic for the machine’s step motors and current polarity reversing relay block shown in fi g. 5. Fig. 5. Joint control circuit of machine stepper motors and relay unit To time the machine’s driven element step motors control with the relay block operation, we developed special SW for automatic control of step motors and relay block shared operation. Special software interface is shown in fi g. 6. In the SW interface, there are fi elds to display axis motion coordinates, area for axis movement manual control, window to display the set process sequence and enter the required values as well as virtual bar to select the program codes. Besides, using the interface, one can specify the PC COM port to be used, manipulate, safe and open process sequence fi les, start/stop/terminate program execution, monitor line current polarity and voltage, retrieve error messages, delete fi les. Apart from the underlying codes, such as G00 – fast positioning. G01 – linear interpolation. М3 – spindle rotation activation and М5 – spindle rotation deactivation, special codes were developed and introduced. For example, М7 – current polarity reversing activation/deactivation commands, М8 – direct current polarity activation, М10 – reverse current polarity activation, and М11 – switch to interactive control of current polarity. Duration of the set polarity current pulse is set in an interactive way from the indication unit using the data display panel, shown in fi g. 7. In fi g. 8 an analytic model to test the developed process sequence is presented for shared operation of the machine’s CNC system and the current polarity switching control system when changing the material to be machined from material 1 to material 2, namely, for the grinding wheel movement along the Z axis. In fi g. 9 readings of the indication unit display, used for interactive operation, obtained during the experiment are presented.

OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 1 4 Fig. 6. Software Interface Fig. 7. Data display block for interactive operation Fig. 8. Design circuit for testing the control program a b Fig. 9. Display unit display readout: a – display readout for current of direct polarity; b – display readout for current of reverse polarity

OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 1 2024 Current time is displayed in the dark background fi eld, the time reference point is fi xed. The reverse or direct polarity current pulse duration is displayed in the light background fi eld. As it can be seen from the readings, set duration of the direct polarity current pulse is 10 s, duration of the reverse polarity current pulse is 5 s. With the grinding wheel movement along the Z axis programmed as 10 mm and 5 mm at a speed of 1 mm×s−1, time for movement is also equal to 10 s and 5 s. Thus, the machine’s CNC system and current polarity switching control system were timed. Conclusion The investigation results demonstrate that using the developed hardware and software package, it is possible to time the machine’s CNC system that controls the driven elements operation and the current polarity switching automatic control system during electrochemical diamond grinding, thus, making a considerable contribution to enhanced performance of CNC machines. It is estimated that the fi eld of future investigation is in fi ne-tuning of electrochemical diamond grinding process with current polarity alternation, using CNC machines and developed hardware and software package for automatic control as well as the package upgrade for other types of mixed processing. References 1. KozlovA.M.Opredelenieparametrovrabochei poverkhnosti abrazivnogo instrumentanaosnovemodelirovaniya [Determination of parameters of the working surface of an abrasive tool based on modeling]. Izvestiya vysshikh uchebnykh zavedenii. Mashinostroenie = Proceedings of Higher Educational Institutions. Маchine Building, 2005, no. 1, pp. 51–55. 2. Kozlov A.M., Bolgov D.V. Modelirovanie sovmeshchennoi abrazivnoi obrabotki [Modelling of fetch abrasive fi ltering]. Fundamental’nye i prikladnye problemy tekhniki i tekhnologii = Fundamental and Applied Problems of Engineering and Technology, 2010, no. 2 (280), pp. 50–53. 3. Popov A.Y., Rechenko D.S., Averkov K.V., Sergeev V.A. High-speed grinding of ZhS6-K high-temperature nickel alloy. Russian Engineering Research, 2012, vol. 32 (5–6), pp. 511–512. DOI: 10.3103/S1068798X12050176. 4. Rechenko D.S., Popov A.Y., Titov Y.V., Balova D.G., Gritsenko B.P. Ultra-high-speed sharpening and hardening the coating of carbide metal-cutting tools for fi nishing aircraft parts made of titanium alloys. Journal of Physics: Conference Series, 2019, vol. 1260 (6), p. 062020. DOI: 10.1088/1742-6596/1260/6/062020. 5. Popov V., Rychkov D., Arkhipov P. Defects in diamonds as the basic adhesion grinding. MATEC Web of Conferences, 2017, vol. 129, p. 01003. DOI: 10.1051/matecconf/201712901003. 6. Soler Ya.I., Kazimirov D.Yu., Prokop’eva A.V. Optimizing the grinding of high-speed steel by wheels of cubic boron nitride. Russian Engineering Research, 2007, vol. 27 (12), pp. 916–919. 7. Roshchupkin S., Kharchenko A. Method of building dynamic relations, estimating product and grinding circle shape deviations. MATEC Web of Conferences, 2018, vol. 224, p. 01001. DOI: 10.1051/matecconf/201822401001. 8. Bratan S., Roshchupkin S., Chasovitina A. The correlation of movements in the technological system during grinding precise holes. Materials Science Forum, 2021, vol. 1037, pp. 384–389. DOI: 10.4028/www.scientifi c.net/ MSF.1037.384. 9. Vasil’ev E.V., Popov A.Y., Lyashkov A.A., Nazarov P.V. Developing a machining strategy for hard-alloy polyhedral inserts on CNC grinding and sharpening machines. Russian Engineering Research, 2018, vol. 38 (8), pp. 642–644. DOI: 10.3103/S1068798X18080166. 10. Vasil’ev E.V., Popov A.Y. Renovation of hard-alloy end mills on numerically controlled grinding machines. Russian Engineering Research, 2014, vol. 34, pp. 466–468. DOI: 10.3103/S1068798X14070144. 11. Borisov M.A., Lobanov D.V., YanyushkinA.S., Skeeba V.Yu. Investigation of the process of automatic control of current polarity reversal in the conditions of hybrid technology of electrochemical processing of corrosion-resistant steels. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2020, vol. 22, no. 1, pp. 6–15. DOI: 10.17212/1994-6309-2020-22.1-6-15. (In Russian). 12. Bratan S., Bogutsky B., Roshchupkin S. Development of mathematical model of material removal calculation for combined grinding process. Proceedings of the 4th International conference on industrial engineering ICIE 2018. Cham, Springer, 2019, pp. 1759–1769. DOI: 10.1007/978-3-319-95630-5_189.

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