KSHP. OMD №1-2016

Vdovin S.I., Lunin K.S.

Pipe bending on the round cam with a longitudinal compression

The article offers a new approach to a theoretical estimate of the sizes of the deformed section. Similar to the traditional energy approach approximating dependences with unknown parameters with the difference allowing output ratio from the conditions of static equilibrium. Numerical solution of the problem allows to avoid some serious assumptions typical to the analytical methods. The application of longitudinal compression to the flexible tube reduces distortion of the sections and, in principle, eliminates the reduction of their height. According to the schedules given in the article, with small radius flexible (about two pipe diameters) is zero, the increment of the height of the cross-section is achieved by application of a longitudinal load component 0,45 ultimate strength elastic compression. With increasing radius specified flexible load decreases. At large angles and bending the longitudinal compressive force may cause plastic deformation of opposite sign in the part of the tube adjacent to the lock cam. This feature of the process limits the possibilities of flexible tubes without distortion of the cross sections, but their ovalization in any case can be reduced.
Keywords: discharge voltage flexible; approximation of the displacement field; the equilibrium equation.

Lebedinsky I.N.

Deformation during free dispensing of a hollow workpiece

The article describes the features of free dispensing of a hollow workpiece. There is developed calculation method of deformation under free dispensing with the division of the total work of deformation on the distribution work while preserving the initial cross-section of the workpiece, with the definition of the corresponding diameter of the workpiece, which corresponds to zero friction and the work associated with increasing cross-sectional area. The magnitude of the normal pressure on the mandrel is determined. The power distribution, which determines the possibility of its implementation on the condition of stability of the workpiece is identified.
Keywords: deformation; dispensing; friction on the mandrel; the degree of deformation.

Chudin V.N.

Forming of body shells with stiffeners

The technological scheme and the calculation process of the manufacture of shells with internal ribs are presented in the article. The process involves the upsetting operation and connection pressure. The state is adopted tough plasticity and creep. The results of experimental work are given. It is revealed that this process depends on values of precipitation, holding pressure and time of discharge. They are interrelated and should be established by the calculation
Keywords: plasticity; creep; time; strain; tension; pressure; relaxation.

Kirianova М.N., Panchenko E.V.

Reduction of the wall different thickness during superplastic forming of large hemispherical shells

Was proposed technological scheme of production of superplastic forming large hemispherical shells with a minimum amount of the wall different thickness. On the basis of mathematical modeling were made theoretical studies of the proposed scheme forming hemispheres.
Keywords: superplastic forming; hemispherical shell; wall different thickness; finite-element simulation.

Makovei V.A., Protsenko P.Yu., Melnik V.S.

Profiling helical heat exchanger tubes by spinning operation

Developed technologies and an experimental production to screw-cutting lathe of helical heat exchanger tubes was conducted in several schemes: one-start – using profiled mandrel, using bulk material instead of the mandrel, profiling without mandrel and bulk material, three-start – using three-roll spinning-head. The simulation of several options roller spinning one- and three-start helical groove on the tube using a software package Deform 3D was conducted. The effect of various parameters (diameter roller Dp, screw pitch of the tube k, groove depth h, frequency of rotation of the mandrel n) on the formation of helical grooves on the tube was investigated. It was found that the greatest impact on the stress-strain state in the process of production of such tubes has a helical pitch of the mandrel.
Keywords: roller spinning; one- and three-start helical tube; stress-strain state; three-roll spinning-head.

Romanenko V.P., Fomin A.V., Sevastyanov A.A.

The use of hollow billets for the production of railway wheels

The article presents the research results of the application of a hollow workpiece, prestitched in the mill helical rolling, for the production of railway wheels. Computer modeling of technological operations (loose sediment, and sediment distillation in technological ring, forming of forgings wheel) using a computing program complex Deform 3D. On the basis of theoretical and experimental studies is shown the principal possibility of production of railway wheels with a diameter of 957 mm from the workpiece obtained by the firmware of the original wheel steel ingots in the mill helical rolling, without changing the existing technological modes. Wheels obtained from the use of this piece, have a higher plastic properties, compared with wheels made according to the based technology. Impressive results are obtained during testing metal wheels impact toughness at various temperatures.
Keywords: Deform 3D; train wheels; a hollow workpiece; screw rolling; plastic properties; modes.

Tikhonov A.K., Minin A.V., Chervyakov A.A., Chikurov A.V., Trotsic V.I.

New technology of local hard chromium plating of large-sized stamps in duct electrolyte

The article is devoted to the study of hard chromium plating of large-size stamping dies for deep drawing. The basic methods of hard chromium plating, as well as the advantages of using this method are presented. Besides the basic difficulties of the chrome plating of large parts are shown.
There is presented the innovation technology of local chromium plating of large-sized products, which eliminates or reduces the problems associated with the classical technology of chrome plating. All the processes of preparation and coating application for the proposed technology are made in the local tub with a small working volume. The installation has a closed loop with minimal discharge of pollutants. Due to the technological bath feeding costs on materials significantly reduced. This technology does not involve the use of lifting mechanisms for moving large parts in the coating process.
The developed technology allows increasing the productivity of press lines and stamping production enterprises due to the increased durability of the coating up to 500 000 cycles or more, reducing the downtime of the stamping lines and also contributes to a substantial decreasing in the marriage of forgings during the transition to hot-galvanized steel.
Keywords: hard chromium plating; large-size stamping dies; deep drawing; local chromium plating of large-sized products.

Tyurin V.A.

Evaluation of simulation of forging with macroshifts

It is considered in the article deformation effects during forging–drawing operations in dies with intersecting working surfaces. Study of the configuration of the deformation zone is made with computer simulations, experiments on physical models – physical slip lines on steel 20 and the laminated blanks from clay, as well as analytical method of constructing fields of slip lines.
Keywords: modeling; forging; macro shifts; deformation zone.

Shitikov A.A., Krivenko G.G., Harseev V.E., Emelyanov V.V., Gribanov A.S., Khomutov M.G.

Modeling of process of stamping of a part «Turbine shell» from heat-resistant alloy ЭP666 for obtaining of the optimal microstructure

In the work with the help of mathematical modeling in software package Deform a study of the process of stamping forgings «turbine housing» from the from heat-resistant alloy ЭП666. The simulation was performed taking into account the changes in the microstructure due to recrystallization and grain growth.
Keywords: stamping heat-resistant alloys; math modeling; DEFORM; microstructure; recrystallization.