Cutting & Tools in Technological System

A REVIEW OF ADDITIVE MANUFACTURING TECHNOLOGIES AND THEIR APPLICATIONS IN THE MEDICAL FIELD

Andra Tirnovean — 2024-12-07

This review paper contains a literature survey about some additive manufacturing technologies and their medical use. Additive Manufacturing is a generic term referring to several technologies used to create physical models or prototype parts based on 3D drawings. Additive Manufacturing models can be used for various testing methods. The paper summarizes the application of Additive Manufacturing Technologies in medicine. It describes the main steps for how to create 3D models for medical applications. Some details can be found on the topics: Data acquisition using medical scanners; Data transformation; Creation of virtual 3D models; Surgical planning and simulation on the virtual 3D model; and Creation of Physical 3D Models for Additive Manufacturing Technologies. 3D physical models can be extremely useful in planning complex surgical interventions, which can be simulated on these models before the actual procedure.

COLOR VISUALIZATION OF 3D-MODELS FOR ENHANCED PREPARATION OF ADDITIVE MANUFACTURING PROCESSES

Yaroslav Garashchenko — 2024-12-07

The main aspects of color visualization of triangulated models of industrial products are presented. The implementation of visualization capabilities is based on RGB and HSV color models. The structure and key features of the software implementation of color visualization and the export of the displayed image in PLY, and AMF formats are discussed. Methods for transformations between RGB and HSV color models are described, as well as an algorithm for coloring the triangular faces of the model based on specified color ranges. The developed algorithms allow for a sufficiently informative representation of the desired areas of the product's surfaces by significantly altering one color component while minimally changing the other two. This is achieved by directing the assignment of functional dependencies and value ranges for each component of the color model. Examples of various methods for color shading of vertices and/or edges and/or faces of the model are provided. The visualization subsystem enables the analysis of the geometric characteristics of the polygonal model during the preparation phase of additive manufacturing processes. Significant advantages of these approaches to color visualization are evident when adapting the product design to technological requirements (design preparation) and when solving optimization tasks in technological preparation. The developed software is integrated into the technological preparation system for manufacturing enterprises in the machine engineering sector. This research was developed at the Department of "Integrated Technologies of Mechanical Engineering" named after M. Semko of NTU "KhPI".

ADDITIVE TECHNOLOGIES IN CONSTRUCTION: TECHNICAL, ECONOMIC AND MANAGEMENT ANALYSIS

Yaroslav Garashchenko — 2024-12-07

The study is devoted to a comprehensive analysis of the introduction of additive technologies into modern construction production, revealing the technical, economic, and managerial aspects of concrete 3D-printing of architectural structures. The work systematically analyzes the evolution of additive manufacturing technologies and identifies the main structural types of 3D-printers (an additive machine for layer-by-layer construction of objects), including portal, robotic, mobile, and hybrid systems. A detailed study of the technological parameters of concrete 3D-printing with concrete mixtures is presented, in particular, optimal printing speed modes, layer parameters, criteria for shaping and quality of building structures. A comparative analysis of the technological capabilities of leading world equipment manufacturers, such as ICON, COBOD International, Apis Cor, and WinSun, is conducted. The economic analysis demonstrates significant advantages of additive technologies: reduction of construction time by 2-6 times, reduction of construction cost by 20-35%, and increase in the load-bearing capacity of structures. The study comprehensively explores the structure of capital and operational expenses associated with technology implementation. Special emphasis is placed on the management aspects of introducing additive technologies, highlighting the critical need for an interdisciplinary approach and knowledge integration across architecture, engineering, management, and computer modeling. The study determines the prospects for the development of concrete 3D-printing technology in the construction industry and outlines the main directions of further scientific research and practical implementation of innovative solutions. This study was developed between the Department of "Integrated Technologies of Mechanical Engineering" named after M. Semko of NTU "KhPI" and "Geopolimer" LTD to implement innovative technologies in the construction industry.

THE INFLUENCE OF DIFFERENT HARDNESS OF THE TOOL MATERIAL ON THE WEAR OF SHM GRINDING WHEELS AND THE SPECIFIC ENERGY INTENSITY OF GRINDING

Valerii Lavrinenko — 2024-12-07

It was established that conditionally viscous-brittle tool materials (high-speed steels and hard alloys) behave in the same way with an increase in hardness: wheel wear and the specific energy consumption of their grinding decrease. As the hardness of brittle tool oxide-carbide ceramics increases, both wheel wear and the specific energy consumption of grinding, on the contrary, increase. That is, an increase in the hardness of viscous-brittle materials facilitates the separation of elementary chips, less energy is needed for this, and accordingly the wear of the wheel and the specific energy consumption of their grinding are reduced. On brittle ceramics, with increasing hardness, there is no change in chip removal, but harder sludge becomes more abrasive and, as a result, the wear of the wheel and the specific energy consumption of their grinding increase. The conclusion from the literature that hard and less plastic materials require relatively less specific energy for grinding is confirmed by us when comparing materials of approximately the same hardness - hard alloys and ceramics. In ceramics, the energy consumption of grinding is actually four times lower than that of hard alloys.

DETERMINATION OF THE STABILITY PERIOD OF TURNING CUTTERS FOR HEAVY MACHINE TOOLS

Galyna Klymenko — 2024-12-07

To determine the optimal cutting modes under conditions of increased requirements for the stability of technological processes, it is necessary to take into account the value of the tool life with a given probability. In this paper, the stability dependence for prefabricated cutters used on heavy machine tools with maximum diameters Dmax = 1250-2500 mm is specified using the group argumentation method. The study presents a new mathematical model that establishes the relationship between tool fracture resistance and key operational parameters. This model incorporates the probabilistic nature of tool performance, which allows for a more accurate assessment of the impact of part size variation, cutting conditions, and process variability. The proposed relationship facilitates the determination of cutting modes that not only increase tool stability but also ensure the reliability and efficiency of heavy machine tools in industrial environments. This mathematical dependence makes it possible to take into account the variation of workpiece parameters and cutting modes, which is especially important when working with large-sized parts on heavy-duty machine tools. The results of the study are of practical importance for industry, as they make it possible to increase the sustainability and productivity of technological processes.

PROGRESS AND CHALLENGES IN PLUNGE MILLING: A REVIEW OF CURRENT PRACTICES AND FUTURE DIRECTIONS

Afraa Khattab — 2024-12-07

This review examines recent advancements and ongoing challenges in plunge milling. It is an increasingly utilised machining process renowned for its high material removal rates, particularly with hard-to-machine materials like hardened steels and titanium alloys. Plunge milling’s unique perpendicular tool path offers enhanced stability and reduced lateral cutting forces, making it valuable for applications that demand precision and efficiency, such as aerospace and automotive manufacturing. The paper systematically analyses and synthesises research on critical areas of plunge milling optimization, including tool geometry, material selection, coating technologies, and process parameters, highlighting strategies to mitigate common issues like rapid tool wear and chip evacuation difficulties. In this comprehensive overview, the review introduces theoretical and experimental findings on optimizing plunge milling tools and process parameters—such as cutting speed, feed rate, and coolant delivery—that are essential for improving performance and achieving desirable surface finishes. The paper also explores innovative trends, including AI-driven optimization algorithms and hybrid machining systems, which hold promise for addressing persistent limitations and enhancing plunge milling’s industrial applicability. By consolidating findings from recent studies, this review contributes to a deeper understanding of plunge milling’s role in high-precision manufacturing and identifies future research directions for advancing the process. The insights presented offer practical and strategic implications, aiming to guide ongoing developments in plunge milling technology and its adoption across various precision-oriented industries.

THE ESSENCE OF THE PROCESS OF VIBRATIONAL FINISHING AND CLEANING, ITS TECHNOLOGICAL CAPABILITIES AND WAYS TO INCREASE EFFICIENCY

Andrii Mitsyk — 2024-12-07

The main provisions of the classification of the vibration processing process depending on the characteristics and composition of the processing medium are given. It is established that vibration processing is a mechanochemical removal of metal particles and its oxides, and plastic deformation of the microroughness of the surface of the part. It was found that vibration processing is related to mechanical dynamic processes, when using chemically active solutions it is related to mechanochemical processes, according to technological purpose to dimensionless processes, according to the type of tool – to processing with free abrasives. It was determined that vibration processing is characterized by the dynamic mechanochemical effect of abrasive medium granules on the treated surface and the acoustic effect of shock waves. It has been established that the features of mechanical and physicochemical phenomena of vibration processing differ in the physical properties of the granules of the medium, the characteristics of the material of the processed parts, the dynamic nature of the process, the composition and properties of the chemically active solution. A classification of defects in the formation of parts, controlled parameters and vibration processing operations is given. The technological capabilities of the processing are presented, these are micro-cutting and surface plastic deformation, the effect of variable accelerations and continuous application of micro-impacts to the surface being processed, which ensures the dynamic nature of the process and creates conditions for strengthening and stabilizing processing. The design of the vibration machines allows the use of various compositions of solid, liquid and mixed compositions of working media. To increase the efficiency of the process, a variable scheme for combining technical solutions of new varieties of the vibration processing process is proposed. It has been established that by combining various combinations of technological and design parameters it is possible to expand the scope of application of the vibration finishing and cleaning process based on the creation and implementation of its varieties.

INFLUENCE OF HELICAL CUTTING-EDGE ANGLE ON END-MILLING STABILITY

Sergei Dyadya — 2024-12-07

Increasing productivity, machining accuracy and efficient use of resources are important priorities for companies that manufacture competitive products. One of the main problems that hinders these processes is the vibration that occurs during cutting. Various methods are used to suppress vibration, one of which is the use of tools with a variable helical cutting-edge angle. However, when choosing the cutting-edge angle, it is important to consider the types of vibrations that occur during cutting, as they directly affect the efficiency of the milling process. In addition, the use of tools with different cutting-edge geometries, such as wavy, gives positive results in roughing, but becomes ineffective in finishing. The purpose of this paper is to study the effect of the helical cutting-edge angle on the stability of the end-milling at different cutting speeds. Both theoretical aspects and experimental data are considered, which make it possible to evaluate the effectiveness of using tools with different angles of inclination to ensure the stability of the machining process and increase productivity while minimizing vibrations in the most unfavorable third speed zone of oscillations for cutting. To conduct the experiments, a special stand was used to adjust the stiffness of the workpiece, record the vibrations that occur during cutting, and the time of contact between the workpiece and the tool. The milling was performed in the third high-speed oscillation zone using a tool whose design provides for the possibility of adjusting the angle of inclination of the helical cutting edge. Studies confirm that changing the angle of inclination can significantly affect the stability of the milling process, reducing the intensity of oscillations and improving machining accuracy. However, this effect depends on the initial cutting conditions, such as the cutting speed. With its increase, the amplitude of the accompanying free oscillations increases, regardless of the value of the angle of inclination. Ensuring the stability of the end-milling in the third speed zone by changing the angle of inclination is possible only at the speeds that determine the beginning of this zone. However, within the entire speed range covered by the third speed zone, it is impossible to ensure a stable milling process only due to the angle of inclination. The study emphasizes the importance of an integrated approach to selecting cutting parameters to achieve process stability.

ASSESSMENT OF THE ROOT MEAN SQUARE DEVIATION ON SURFACES MACHINED BY HIGH-FEED TANGENTIAL TURNING

István Sztankovics — 2024-12-07

Recent advancements in machining focus on precision, efficiency, and handling harder materials, driven by sectors like aerospace and automotive. Hard machining, or processing materials over 45 HRC, presents challenges such as rapid tool wear, intense heat, and maintaining dimensional accuracy. Innovations in cutting tool materials and CNC technology have improved these processes, but tool degradation and high forces still complicate machining hardened materials. Surface roughness is a key quality metric, impacting performance factors like wear resistance and fatigue life. By optimizing cutting parameters, manufacturers aim to achieve consistent surface finishes, essential for durability in demanding applications. In this paper, the effect of the input parameters (depth of cut, feed, and cutting speed) are analysed on selected surface roughness parameters. The setup parameters were selected according to the full factorial design of experiment method. The results showed that higher feed rates resulted in rougher finishes, leading to greater spacing between profile elements and steeper surface profiles in the studied range.

CORRELATION ANALYSIS BETWEEN COMPONENTS OF FORCE AND VIBRATION IN TURNING OF 11SMN30 STEEL

Tanuj Namboodri — 2024-12-07

Workability of material is defined as the ease of operating on it. 11SMn30 is widely used material in automobile manufacturing industries. Cutting forces have been shown to be the most effective measure for understanding metal machining processes. The forces which helps in performing machining operation also affects the cutting tool, in terms of deformation, bend, wear, which leads to the vibration in the machining system, This article aims to study the correlation between feed, components of cutting forces and components of vibration in turning of 11SMn30 steel grade using dynamometer and MPU6050 sensor.

INFLUENCE OF DIAMOND BURNISHING ON CORE HEIGHT AN TEN-POINT HEIGHT

Viktoria Ferencsik — 2024-12-07

Diamond burnishing is a cold plastic forming process, which used as surface improvement finishing treatment after conventional chip removal procedures. This paper presents the experimental study of the impact of different burnishing parameters on 3D surface roughness on cylindrical low alloyed aluminium workpieces. To carry out comparative analysis, measurement of surface roughness was implemented before and after burnishing with an Altisurf 520 measuring device. The results enable a more accurate understanding of the processes that take place during the procedure and, for industrial applications, can help reduce machining time and costs by better defining the set-up parameters.