Vol. 26 No. 2 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. 2 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. 2 2024 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Gaikwad V., Chinchanikar S. Investigations on ultrasonic vibration-assisted friction stir welded AA7075 joints: Mechanical properties and fracture analysis........................................................................................................................ 6 Sirota V.V., Zaitsev S.V., Limarenko M.V., Prokhorenkov D.S., Lebedev M.S., Churikov A.S., Dan'shin A.L. Preparation of coatings with high infrared emissivity.......................................................................................................... 23 Babaev A.S., Kozlov V.N., Semenov A.R., Shevchuk A.S., Ovcharenko V.A., Sudarev E.A. Investigation of cutting forces and machinability during milling of corrosion-resistant powder steel produced by laser metal deposition............. 38 Dolgova S.V., Malikov A.G., Golyshev A.A., Nikulina A.A. The eff ect of laser surfacing modes on the geometrical characteristics of the single laser tracks............................................................................................................................... 57 Karlina Y.I., Kononenko R.V., Popov M.A., Deryugin F.F., Byankin V.E. Assessment of welding engineering properties of basic type electrode coatings of diff erent electrode manufacturers for welding of pipe parts and assemblies of heat exchange surfaces of boiler units............................................................................................................................. 71 Yanpolskiy V.V., Ivanova M.V., Nasonova A.A., Yanyushkin A.S. Determination of the rate of electrochemical dissolution of U10A steel under ECM conditions with a stationary cathode-tool............................................................... 95 EQUIPMENT. INSTRUMENTS Zakovorotny V.L., Gvindjiliya V.E. The study of vibration disturbance mapping in the geometry of the surface formed by turning............................................................................................................................................................................. 107 Gasanov B.G., Konko N.A., Baev S.S. Study of the kinetics of forming of spherical sliding bearing parts made of corrosion-resistant steels by die forging of porous blanks............................................................................................... 127 Gvindjiliya V.E., Fominov E.V., Moiseev D.V., Gamaleeva E.I. Infl uence of dynamic characteristics of the turning process on the workpiece surface roughness........................................................................................................................ 143 Lobanov D.V., Skeeba V.Yu., Golyushov I.S., Smirnov V.M., Zverev E.A. Design simulation of modular abrasive tool........................................................................................................................................................................................ 158 MATERIAL SCIENCE EroshenkoA.Yu., Legostaeva E.V., Glukhov I.A., Uvarkin P.V., TolmachevA.I., Sharkeev Yu.P. Thermal stability of extruded Mg-Y-Nd alloy structure.................................................................................................................................. 174 Bazaleeva K.O., Safarova D.E., Ponkratova Yu.Yu., Lugovoi M.E., Tsvetkova E.V., Alekseev A.V., Zhelezni M.V., Logachev I.A., Baskov F.A. The infl uence of technological parameters of the laser engineered net shaping process on the quality of the formed object from titanium alloy VT23......................................................... 186 Efi movich I.A., Zolotukhin I.S. Oxidation temperatures of WC-Co cemented tungsten carbides....................................... 199 Pribytkov G.A., Baranovskiy A.V., Firsina I.A., Akimov K.O., Krivopalov V.P. Study of Fe-matrix composites with carbide strengthening, formed by sintering of iron titanides and carbon mechanically activated mixtures................ 212 EDITORIALMATERIALS 224 FOUNDERS MATERIALS 235 CONTENTS
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 2 4 Design simulation of modular abrasive tool Dmitry Lobanov 1, a, Vadim Skeeba 2, b, Ivan Golyushov 1, c, Valentin Smirnov 1, d, Egor Zverev 2, e 1 I. N. Ulianov Chuvash State University, 15 Moskovsky Prospekt, Cheboksary, 428015, Russian Federation 2 Novosibirsk State Technical University, 20 Prospekt K. Marksa, Novosibirsk, 630073, Russian Federation a https://orcid.org/0000-0002-4273-5107, lobanovdv@list.ru; b https://orcid.org/0000-0002-8242-2295, skeeba_vadim@mail.ru; b https://orcid.org/0000-0001-9757-1368, ivan.golyushov.97@mail.ru; d https://orcid.org/0000-0003-2721-9849, vms53@inbox.ru; e https://orcid.org/0000-0003-4405-6623, zverev@corp.nstu.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. 2 pp. 158–173 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2024-26.2-158-173 ART I CLE I NFO Article history: Received: 07 March 2024 Revised: 21 March 2024 Accepted: 27 April 2024 Available online: 15 June 2024 Keywords: Abrasive tools Modular grinding wheel Tool design Simulation Funding This research was funded by Russian Science Foundation project N 23-29-00945, https://rscf.ru/en/ project/23-29-00945/ Acknowledgements The research was carried out at the equipment of the Engineering Center “Design and Production of High-Tech Equipment” and the shared research facility” Structure, mechanical and physical properties of materials”. ABSTRACT Introduction. Grinding is one of the most common types of finishing. It allows the production of surfaces with the required quality parameters and is one of the most available and productive methods for machining high-strength and difficult-to-machine materials. Grinding wheels represent the most prevalent application of grinding technology in mechanical engineering. The use of this abrasive tool helps to increase processing productivity by ensuring the removal of a significant layer of material. In addition, grinding wheels have a longer service life and are widely used in the implementation of hybrid technologies based on the combination of mechanical (abrasive), electrical, chemical, and thermal effects in various combinations. A variety of tool body shapes and types of abrasives allow the use of wheels in a wide variety of production areas. One of the ways to analyze and design a new tool is numerical simulation. In this research, graphic modeling was selected as the most appropriate method for representing the future design of the tool. This approach allows for a more straightforward conceptualization process compared to other modeling techniques. The purpose of the work is to simulate a modular abrasive tool in order to analyze and synthesize structures to increase the efficiency of tool support for the manufacture of products made of high-strength and difficult-to-process materials using traditional or hybrid processing technologies. Research methodology. Theoretical studies are carried out using the basic principles of system analysis, geometric theory of surface formation, cutting tool design, graph theory, mathematical and computer simulation. To solve the problem, we have studied the available designs of modular grinding wheels. There has also been the analysis of the types of abrasive parts, methods of fastening of the abrasive cutting part on the wheel’s body, the materials used for the manufacture of the body, the characteristics of the body of the wheel, and fastening schemes. Results and discussions. A simulation technique based on graphic modelling theory has been developed. A comprehensive investigation of the existing design of the grinding wheel has enabled the identification of the key structural elements that define its design. The data obtained has been used to create a generalized graphic simulation of a modular abrasive tool. This simulation integrates all the components and displays a conditional constructive relationship between them. The developed design methodology was tested on an example of two designs of modular grinding wheels. The theoretical studies established that the design efficiency of modular abrasive tools can be increased by 2–4 times by using the developed simulation technique. For citation: Lobanov D.V., Skeeba V.Yu., Golyushov I.S., Smirnov V.M., Zverev E.A. Design simulation of modular abrasive tool. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2024, vol. 26, no. 2, pp. 158–173. DOI: 10.17212/1994-6309-2024-26.2-158-173. (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 Introduction The quality requirements for products manufactured by machine-building enterprises are increasing every year. This, in turn, leads to the introduction of more traditional and hybrid finishing technologies as well as smoothing ones. Grinding is one of the most common types of finishing used in shaping processes to
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 2 2024 form a surface with the required quality parameters. It is one of the most available and productive methods for machining high-strength and difficult-to-machine materials [1–6]. The fundamental range of abrasive tools used in manufacturing processes encompasses grinding and cutting wheels, in addition to heads and bars and other types of cutting equipment. Furthermore, there are also less common types of tool designs [7]. In mechanical engineering, grinding wheels are one of the most popular tools for machining parts due to its high efficiency. The use of this type of tools enables the removal of a significant layer of material. Additionally, grinding wheels have a longer service life and are widely used in modern hybrid technologies [8–17]. These technologies provide mechanical (abrasive), electrical, chemical, and thermal treatment in various combinations [18–31] to achieve unique results in processing. The variety of shapes and types of abrasive materials allows grinding wheels to be adapted to a wide range of production applications, ensuring its use in multiple manufacturing areas. The choice of modular grinding wheels as an object of research is due to a series of strategic advantages that make its use a profitable and effective solution in various industrial sectors: 1. Abrasive material saving. In modular grinding wheels, the main part is the body, which can be made of steel or aluminum alloys. This means that the abrasive material is used only in the part that is immediately involved in the grinding process. The use of more expensive and high-quality abrasive materials where really needed without increasing the total cost of the wheel helps to reduce costs. 2. The possibility of the wheel body reuse. Since the body of the modular grinding wheel does not wear out during use (it is not in immediate contact with the surface), it can be reused. When the abrasive part wears out, the body can be fitted with a new one, reducing the need to replace the entire wheel and helping to save resources and costs. 3. The flexibility of replacing the abrasive part. Another significant advantage of modular wheels is that only the abrasive part of the wheel can be replaced. The designer can select a material with a different abrasive type or grit size depending on the current application while retaining the wheel body. This flexibility of modular wheels allows creating highly efficient tools for a variety of machining operations while minimizing the need to own a large number of specialized devices [32–35]. For this reason, modular grinding wheels are the preferred choice for many production applications. Its economic and technological efficiency make it the ideal solution for ever-increasing demands for machining quality, reduced production costs, and longer tool life. One of the promising methods for improving the performance of modular grinding wheels is to develop designs that reduce heat generation in the machining area during grinding. Wheel designs with an interrupted working part are capable of reducing the temperature in the machining area to an acceptable level, below which structural and phase changes in the machined material do not occur [36–41]. The choice of abrasive wheel plays an important role in the machining process [42–44]. After all, many parameters depend on the correct wheel choice, such as productivity, the quality of the machined surface, the cost of the tool, and, consequently, the finished part and the life of the abrasive wheel. However, the range of grinding wheels has expanded to such an extent that it has become challenging to select the optimal tool for a given task. Solving this problem requires careful analysis and verification of a large amount of collected information. Sometimes, the only possible solution is the development of a new and unique tool design that will contribute to the realization of the given task. Numerical simulation plays a major role in the analysis and design of new tools, integrating a multitude of techniques [45], each of which has its own distinctive advantages and applications. In our study, we selected graph modeling [46] as the optimal methodology because this simulation not only enables us to effectively analyze and visualize the relationships and dependencies between the various components of the designed abrasive tool but also simplifies the process of identifying the key elements and its functional purpose. The purpose of the study is to simulate a modular abrasive tool in order to analyze and synthesize structures and increase the efficiency of tool support for the manufacture of products made of high-strength and difficult-to-process materials using traditional or hybrid processing technologies.
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 2 4 Research methodology Theoretical studies are carried out using the basic principles of system analysis, geometric theory of surface formation, cutting tool design, graph theory, mathematical and computer simulation. The selection of wheels for a manufacturing process takes place in several stages: selection of the abrasive material according to the task; search for the required type of wheel profile, taking into account its industrial purpose; development of a new design of modular grinding wheel. Achieving the required surface quality and productivity in the grinding process depends largely on the wheel used and its characteristics: the combination of machining and abrasive materials, dimensions, wheel design features, as well as the machining conditions and modes. Each of the characteristics described above is important in its own way and has an impact on the machining process. The choice of abrasive material and the determination of the optimum grit size also have an important influence on the grinding process and the achievement of the required product quality parameters. At the same time, it is important to maintain the high productivity of the grinding process [47–49]. The use of simulation in the design solution provides an opportunity to perform tool selection and analysis at various stages of design, as well as process and tool preparation in production. We have developed a simulation technique based on graphic modeling theory in order to effectively solve the tasks set. We have studied the existing designs of modular grinding wheels to solve the problem described above. The types of the abrasive part, the methods of fastening the abrasive cutting part on the body of the wheel, the materials used to manufacture the body, the characteristics of the body of the wheel and the fastening schemes were analyzed [50]. As a result of the analysis of existing wheel designs, the key structural elements are identified that make it possible to describe the design of the grinding wheel. The description of the abrasive part of the grinding wheel is based on the following elements: the design of the abrasive part (solid or segmented); the dimensional characteristics of the abrasive part, which determine the size and accuracy of the production of grinding elements; the abrasive material; the hardness of the wheel; the grit size; the bond; the shape of the elements and its quantity. The body part is defined by the type of its profile; dimensional parameters; material composition (such as steel or aluminum alloys); the presence or absence of coating. The fastening part is characterized by the method of fastening, which encompasses the type of connection of the abrasive part with the body part; the presence or absence of adjusting and fastening screws; its quantity and dimensional parameters. Furthermore, the model contains data about the intended purpose of the wheel; unbalance class; accuracy class; maximum speed; manufacturer information. The data analyzed has been used to construct a generalized graph-based model of modular grinding tool designs. This model contains all the constituent components that are included in the designs of various modular grinding wheels and displays the conditional constructive relationship. The grinding wheel design is a system of separate parts of the wheel design, or interconnected components, and is represented as an oriented graph. ( ) = , G Χ Ε , where X are vertices; E is an illustration of the set X in X or the relationship between the vertices of the graph (represented by connection lines). The relationship between the wheel elements and its characteristics is shown by vertex-edge connections {X1, lx1}, {X2, lx2}, ... etc. Each edge of a connected graph is a set of vertices, which is described by a subset of vertices and a subset of edges. An edge of a graph li is a set of vertices of a graph li Xi and simultaneously consists of elements X1, X2,...Xn, which can also be sets (Fig. 1). Thus 1 n i i i l X = = .
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 2 2024 Let us consider the orientation of the edges and vertices of the graph G = (X, E). The grinding wheel in this case is shown in the form of the following parts: abrasive part (vertex X1), body (vertex X2), fastening (vertex X3), unbalance class (vertex X4), accuracy class (vertex X5), maximum speed (vertex X6), wheel manufacturer (vertex X7) other parameters (additions or notes vertex X8) and other elements (vertices X9...Xn) represented by the set lX.: 1 . n X i i l X = = The abrasive part (vertex X1) is represented by the parameters lX1, which are the vertices of the edge; X11 is the design of the abrasive part; X12 is geometric dimensions; X13 is abrasive material; X14 is grit size; and XlnX1 is other parameters described by the set lX1: 1 1 1 . n X i i l X = = The abrasive part (vertex X11) is described by the parameters that are the vertices of the edge lX11; X111 is a solid cutting part; X112 is the interrupted (segmented) part; and Xnl X11 is other versions presented as a set lX11 11 11 1 n X i i l X = = . The dimensions of the abrasive part (vertex X12) are described by different parameters, which are the vertices of the graph lX12:X121 is the shape of the insert; X122 is the dimensions of the insert; X123 is the height of the abrasive layer; X124 is the width of the abrasive layer; and X125 is the concavity of the abrasive layer. X126 is the design of the insert; Xnl X12 are other parameters represented as a set lX12: 12 12 1 n X i i l X = = . Fig. 1. Graph-based model of a modular wheel
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 2 4 The abrasive material (vertex X13) is better presented in the form of the following variants, which are the vertices of graph lX13: X131 is natural abrasives; X1311 is diamond; X1312 is corundum; X1313 is emery; X1314 is pumice stone; X1315 is quartz; X132 is artificial (synthetic) abrasives; X1321 is synthetic diamond; X1322 is silicon carbide (carborundum); X1323 is boron carbide; X1324 is borazon; X1325 is cubic boron nitride; X1326 is electrocorundum; X1327 is normal electrocorundum; X1328 is white electrocorundum; X1329 is monocorundum; X13210 is zirconium electrocorundum; X13211 is alloyed electrocorundum, represented as a set lX13: 13 13 1 n X i i l X = = . The grit size (vertex X14) is expressed by various versions represented by the vertices of the graph lX14: Х141 – F4; Х142 – F5; Х143 – F6; Х144 – F7; Х145 – F8; Х146 – F10; Х147 – F12; Х148 – F14; Х149 – F16; Х1410 – F20; Х1411 – F22; Х1412 – F24; Х1413 – F30; Х1414 – F36; Х1415 – F40; Х1416 – F46; Х1417 – F54; Х1418 – F60; Х1419 – F70; Х1420 – F80; Х1421 – F90; Х1422 – F100; Х1423 – F120; Х1424 – F150; Х1425 – F180; Х1426 – F220; Х1427 – F230; Х1428 – F240; Х1429 – F280; Х1430 – F320; Х1431 – F360; Х1432 – F400; Х1433 – F500; Х1434 – F600; Х1435 – F800; Х1436 – F1000; Х1437 – F1200; Х1438 – F1500; Х1439 – F2000; ХnlX14 is other variants presented as a set lX14: 14 14 1 n X i i l X = = . The hardness of the wheel (vertex X15) according to DIN ISO 525 standard is represented by the following parameters, which serve as the vertices of the edge lX15: Х151 – F; Х152 – G; Х153 – H; Х154 – I; Х155 – J; Х156 – K; Х157 – L; Х158 – M; Х159 – N; Х1510 – O; Х1511 – P; Х1512 – Q; Х1513 – R; Х1514 – S; Х1515 – T; Х1516 – U; Х1517 – X; Х1518 –Y; Х1519 – Z; Х1520 – V; Х1521 – W; XnlX15 is other options presented as a set lX15: 15 15 1 n X i i l X = = . Type of bond (vertex X16): X161 is metal, X1611...X161n is marking; X162 is ceramic, X1621...X162n is marking; X163 is silicate, X1631...X163n is marking; X164 is magnesian, X1641...X164n is marking; X165 is bakelite, X1651... X165n is marking; X166 is vulcanite, X1661...X166n is marking; X167 is griphthalic, X1671...X167n is marking, represented in the set lX16: 16 16 1 n X i i l X = = . For the wheels with diamond abrasive material (synthetic or natural), the following parameters are also taken into account: Diamond concentration (vertex X13111 and X13211), with these parameters forming the vertex of the graph lX13111: Х131111 – 25 %; Х131112 – 50 %; Х131113 – 75 %; Х131114 – 100 %; Х131115 – 150 %; XnlX13111 is other options. The body of modular grinding wheels GOST R 52781-2007 (vertex X2) is described by the following parameters forming the vertices of the edge lX2: X21 is profile type; X22 is dimensional parameters of the body; X23 is body material; X24 is wear-resistant coating and hardening; Xnl X21 is other parameters described by the set lX2: 2 1 n X i i l X = = . X21 is the profile type, where X211 is type 1; X212 is type 2; X213 is type 3; X214 is type 4; X215 is type 5; X216 is type 6; X217 is type 7; X218 is type 10; X219 is type 11; X21101 is type 12; X21102 is type 14; X2111
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 2 2024 is type 20; X2112 is type 21; X2113 is type 22; X2114 is type 23; X2115 is type 24; X2116 is type 25; X2117 is type 26; X2118 is type 35; X2119 is type 36; X2120 is type 37; X2121 is type 38; X2122 is type 39; described by the set lX21: 21 21 1 n X i i l X = = . X22 is dimensional parameters of the body: X221 is outer diameter of the wheel; X222 is the diameter of the landing hole; X223 is the diameter of the support end; X224 is the thickness of the base part of the body; X225 is the diameter of the undercut; X226 is the radius; X227 is the outer corner of the body cone; X228 is the wheel’s height; X229 is the height of the working part; X2210 is the width of the working part; X2211 is the working angle, represented as a set lX22: 22 22 1 n X i i l X = = . X23 is the body material: X231 is structural steel, X2311 is steel 3; X2312 is steel 20; X2313 is steel 25; X2314 is steel 30; X2315is steel 35; X2316 is steel 45; X2317 is steel U8A; X2318 is steel 0.9 C-Cr-V; X232 is aluminum alloys, X2321 is alloy AK6; X2322 is alloy D16, represented as a set lX23: 23 23 1 n X i i l X = = . X24 is wear-resistant coating and hardening: X241 is type of hardening; X242 is depth of hardening; X243 is coating material; X244 is coating thickness; Xnl X24 is other options; presented as a set lX24: 24 24 1 n X i i l X = = . The fastening of the abrasive part of the prefabricated grinding wheels (vertex X3) is described by the parameters forming the vertex of the graph lX3: X31 is the type of connection of the abrasive part to the body, X32 is adjusting screws, X33 is fixing screws. The fastening part is represented as a set of lX3: 3 3 1 . n X i i l X = = X31 is the type of connection of the abrasive part to the body: X311 is mechanical; X3111 is fastening with a radial screw; X3112 is fastening with an axial nut; X3113 is fastening with an axial bolt; X3114 is fastening with a radial nut; X312 is soldered; X3121 is solder PSr 40 (Ag); X3122 is solder PSr 50 (Ag); X313 is adhesive; X3131 is phenolic rubber adhesive (VK-32-20); X3132 is epoxy resin (ED-6); these connection methods are presented in the form of a set lX31: 31 31 1 . n X i i l X = = X32 is adjusting screws: X321 is the amount of screws; X322 is the thread parameters described by the set lX32: 32 32 1 . n X i i l X = = X33 is mounting screws: X331 is the number of screws; X332 is the thread parameters; Xnl X33 is the other components described by the set lX33: 33 33 1 n X i i l X = = .
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 2 4 The unbalance class (1, 2, 3, 4) is indicated by the vertex X4. The accuracy class (AA, A, B) is indicated by the vertex X5. The maximum allowed processing speed is indicated by the vertex X6. The manufacturer is indicated by the vertex X7. Additional parameters (notes, additions) are represented by the vertex X8. The graph structure proposed for the description of grinding wheel design options allows for the decomposition of any design into its components for providing a comprehensive representation of the wheel. As previously stated, the precise definition of the vertices of the graph allows for the construction of a wheel to be represented as a matrix B, which corresponds to the graph-based model. 11 12 1 21 22 2 1 2 Â j j i i ij b b b b b b b b b = , where ij 1, 0, ij ij n if if ι ∈ ι ι ∉ ι In this instance, the matrix B is employed to illustrate the interrelationship between the design process of the grinding wheel and the selection of optimal parameters for specific tasks. The conversion of the graphic model into a matrix form will result in the creation of a single database of grinding wheel designs, which, in turn, will facilitate the systematization of grinding wheels available at enterprises. In addition, this model can be expanded to accommodate the incorporation of novel components in the structural design. Results and Discussion Using the methodology described above, two designs of modular grinding wheels with different sizes, methods of fastening the abrasive part, and other design features were simulated. The first modular grinding wheel design is represented by a 6A2 diamond surface grinding wheel shown in Figure 2. This wheel has a solid ring-shaped abrasive section that is fastened to the body by phenolic rubber adhesive. The abrasive part is made of Bakelite B2-01 bond and synthetic diamond. The body is made Fig. 2. Surface diamond grinding wheel type 6A2
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 2 2024 of D16 aluminum alloy and is type 6, with body dimensions of 200×20×4×29×76 mm. This wheel has a maximum permitted cutting speed of 50 m/s. This wheel is proposed as a graphic model and shown in Figure 3. Fig. 3. Graph-based model of the wheel type 6A2 200×20×4×29×76 AC6 200/160 B2-01 The present model is a simplified matrix B1, which contains only those elements present in the specific model of the wheel. The components not included in the design are not considered, which reduces the size of the matrix: 111 121 122 123 124 126 1321 13214 1423 152 1652 1 1 2 3 X 1 1 1 1 1 1 1 1 1 1 1 = 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 X X X X X X X X X X X X X Â 216 221 222 223 224 225 228 229 2210 2322 3131 0 0 0 0 0 0 0 0 0 0 0 . 1 1 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 1 X X X X X X X X X X X In order to gain further insight, we may now consider another design of a modular abrasive tool. This wheel has been specifically developed for diamond-abrasive machining [8, 51–52] and is presented in Figure 4. This wheel has an interrupted (segmental) abrasive part in the form of cylindrical heads fastened in the body by radial screws. The abrasive part is made of Bakelite B2-01 bond and synthetic diamond. The body is made of steel and is type 36 with body dimensions 250×10×7×34×51 mm. This wheel has a maximum permitted machining speed of 270 m/s. This wheel is represented by a graphic model and is shown in Figure 5: Now, by analogy, we construct the matrix B2 describing this wheel construction: 112 121 122 123 124 126 1321 13214 1423 152 1652 1 2 2 3 X 1 1 1 1 1 1 1 1 1 1 1 = 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 X X X X X X X X X X X Â X X
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 2 4 Fig. 4. Grinding wheel for diamond abrasive machining When comparing these models, the constructional difference can be clearly seen. In the considered case, the branches X3 (Fig. 3 and Fig. 5), which describe the fastening part, vary on the model because the fastening of the abrasive part is radically different. This can be seen both in the graphs and in the matrices B1 and B2 that describe these models. It can be demonstrated that each wheel design is unique and that when at least one design element is altered, the wheel model also undergoes a corresponding change. Conclusion The study proposes a novel methodology for simulating modular abrasive tools based on graph modeling theory and matrix analysis. This approach allows for comprehensive analysis and synthesis of Fig. 5. Graph-based model of the wheel for diamond abrasive machining 216 221 222 223 224 225 228 229 2210 2322 3111 321 322 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 X X X X X X X X X X X X X
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 2 2024 design solutions, thus enhancing the effectiveness of tool support for the manufacture of products made of high-strength and difficult-to-process materials via conventional or hybrid manufacturing techniques. The generalized graphic model is an innovative approach to the design and analysis of a modular abrasive tool that includes all the key structural elements and characteristics that can be used in such tools. The principal advantage of the model is its flexibility and extensibility, which enables it to be readily updated or augmented with new components to meet current or future abrasive tool requirements. This simulation allows for the visualization of existing abrasive tool designs and the experimentation with the creation of new designs by adding, modifying, or removing certain elements. Such a graphical approach facilitates comprehension of the interactions between the various tool components and its impact on the overall performance and efficiency of the tool. One of the most crucial attributes of a generalized graphic model is its capacity to be represented in a matrix form. Such representation not only enables the systematization and structuring abrasive tools data but also facilitates the process of analysis, synthesis, and the selection of optimal tools. The matrix form of information representation allows for the consideration of the specific characteristics of each tool, thereby providing an effective means for the management of the tooling assortment at the enterprise. This is critical to optimizing production processes and increasing efficiency through more informed tool selection. The developed design methodology was tested on an example of model realization on two designs of modular grinding wheels. The theoretical studies established that the design efficiency of modular abrasive tools can be increased by 2–4 times (depending on the complexity of the tool design) by using the developed simulation technique. References 1. StarkovV.K. Shlifovanie vysokoporistymi krugami [Gringing of high-porouswheels].Moscow,Mashinostroenie Publ., 2007. 688 p. ISBN 978-5-217-03386-7. 2. Bratan S.M., Roshchupkin S.I., Chasovitina A.S., Gupta K. Vliyanie na veroyatnost’ udaleniya materiala otnositel’nykh vibratsii abrazivnogo instrumenta i zagotovki pri chistovom shlifovanii [The effect of the relative vibrations of the abrasive tool and the workpiece on the probability of material removing during finishing grinding]. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2022, vol. 24, no. 1, pp. 33–47. DOI: 10.17212/1994-6309-2022-24.1-33-47. 3. SkripnyakE.G., LobanovD.V., SkripnyakV.V.,YanyushkinA.S., SkripnyakV.A., RychkovD.A. Keramicheskie nanokompozity na osnove diborida tsirkoniya [Ceramic nanocomposites on the basis of zirconium diboride]. Sistemy. Metody. Tekhnologii = Systems. Methods. Technologies, 2011, no. 2, pp. 95–98. 4. Sayutin G.I., Nosenko V.A., Bogomolov N.I. Vybor instrumenta i SOZh pri shlifovanii titanovykh splavov [Choice of tools and coolant for grinding titanium alloys]. Stanki i instrument = Machines and Tooling, 1981, no. 11, pp. 15–17. (In Russian). 5. Smagin G.I., Filimonenko V.N., Yakovlev N.D., Korchagin M.A., Skeeba V.Y. Shlifoval’nyi instrument na osnove silikokarbida titana [The grinding tool on a basis titan silicon karbid]. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2011, no. 1 (50), pp. 27–30. 6. Novoselov Yu.K., Bratan S.M., Bogutskii V.B. Vliyanie sluchainoi sostavlyayushchei otklonenii profilya instrumenta na dinamiku protsessa kruglogo naruzhnogo shlifovaniya [Effect of random component in tool profile deviations upon dynamics of external circular grinding]. Naukoemkie tekhnologii v mashinostroenii = Science Intensive Technologies in Mechanical Engineering, 2016, no. 5 (59), pp. 10–17. 7. Smirnov V.M., Lobanov D.V., Skeeba V.Yu., Golyushov I.S. Povyshenie effektivnosti kontsevogo almaznogo abrazivnogo instrumenta na metallicheskoi svyazke za schet sovershenstvovaniya tekhnologii izgotovleniya [Improving the efficiency of metal-bonded diamond abrasive end tools by improving manufacturing technology]. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2021, vol. 23, no. 2, pp. 66–80. DOI: 10.17212/1994-6309-2021-23.2-66-80. 8. Popov A.Yu., Rechenko D.S., Averkov K.V., Sergeev V.A. Vysokoskorostnoe shlifovanie zharoprochnogo nikelevogo splava ZhS6-K [High-speed grinding of ZhS6-K high-temperature nickel alloy]. STIN = Russian Engineering Research, 2012, no. 2, pp. 32–34. (In Russian).
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