Arkady M. Shitov¹, Doctor of Technical Sciences, Senior Researcher of the Laboratory of the Technological Processes and Systems Control, е-mail:  shitov_am@mail.ru

Igor M. Kondratiev¹, Doctor of Technical Sciences, Senior Researcher of the Laboratory of the Technological Processes and Systems Control, е-mail:  kiimash@yandex.ru

¹ Blagonravov Institute of Mechanical Engineering of the RAS

One of the current trends in machinery is to increase a number of build-in sensors. It allows to ensure multi-parametric conditions monitoring and prevent possible machine tool failures during maintenance. Failure tree analysis (FTA) is used to determine the root causes of failures. By example of machine tool spindle unit FTA usage is described for development of the procedures that increase machine tool reliability and decrease failure rates during maintenance. These goals are achieved by FTA which provides most feasible causes of failures which have the greatest possibilities of implementation. As practice shows exceed of maximum allowable rolling bearing temperature that is resulted in consistent lubricant degradation issues and bearing breakdown is the most feasible cause of machine tool spindle unit failure. Usage of sensors for bearing temperature monitoring enables to prevent these failures. More over the monitoring data allow to predict spindle unit residual operating life. 

 

 

Keywords: diagnostics, reliability, residual operating life, failure tree analysis, sensor, machine tool, spindle unit

References

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Sergey A. Voronov ¹, Doctor of Technical Sciences (habl.), Professor of the Applied Mechanics Dpt., е-mail:  voronov@rfbr.ru

Igor A. Kiselev¹, Doctor of Technical Sciences, Associate Professor of the Applied Mechanics Dpt., е-mail: i.a.kiselev@yandex.ru

¹ Bauman Moscow State Technical University 

The structure of the generalized model of cutting process is considered in the paper. It is demonstrated that full model should involve: model of tool and workpiece dynamics; model of cutting forces; model of new surface formation; model of machined parts shape errors analysis. All components of a full model are nonlinear in general, involving functions with time delay. The analysis of such system is possible numerically only, by simulation, by using the functional analysis methods, FEM and other method of modeling CAE/CAM systems. Some models of tool and workpiece dynamics which are reduced to the second-order in time differential equations in the paper are presented. Models constructed by FEM are analyzed too. The cutting forces which enter into the equations of tool and workpiece dynamics are modeled as the empiric, nonlinear relations depending on given cutting conditions. The empiric coefficients are experimentally determined, or are obtained by modeling of cutting edge digging into the machined material. The example of blade 5-axis milling modeling is presented in the paper.

Keywords: dynamics, cutting process, machining, nonlinear vibrations

References

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Viktor Ovchinnikov¹, Doctor of Technical Sciences (habil.), Academician of International Academy of Informatization, Professor of Material Science Department, e-mail: vikov1956@mail.ru;

¹ Moscow Polytechnic University

In the article the key trends for development of perspective high technology deformed aluminum alloys for welded constructions manufacturing. Recently the Al–Mg–Zn, Al–Mg–Si and Al–Mg–Sc systems of avarege strength aluminum alloys have been developed. There are described trends for improving the chemical composition of new alloys, manufacturing techniques of semi-finished products from them and their thermal processing. Weldability of 1565ch alloy belonging to Al–Mg–Zn system is described. This alloy is to replace the traditional AMg5 alloy in welded constructions. Usage of 1565ch alloy sheets for welded constructions, including constructions operating at cryogenic conditions, allows the constructions mass decries for 8–10 % at the expense of greater strength of the alloy in comparison to AMg5 alloy strength.

 

Keywords: aluminum alloys, deformed alloys, strength, workability, weldability

References

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2. Khokhlatova L.B., Kolobnev N.I., Ovchinnikov V.V. Properties and structure of the 1424 и В-1461 allows’ sheets joins made by friction stir welding // Welding. 2017. No 4. P. 22–26.

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8. 1565ч Aluminum-magnesium alloy for cryogenic using / А.С. Oryschenko, Е.P. Osokin, N. N. Barakhtina et al. // Non-ferrous Metals. 2012. No 11. P. 84–89.

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14. Studying the fatigue life of main metal and welded joints of 1565ч alloy sheets / А.М. Drits, V.V. Ovchinnikov, V.N. Nuzhdin, А.D. Koniukhov // Non-ferrous Metals. 2015. No 12. P. 88–93.

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Roman A. Novoselov¹, Postgraduate Student, e-mail: deemalfy@gmail.com

Asif Yu. Omarov¹, Doctor of Technical Sciences, Senior Researcher, e-mail:  asif.omarov@yandex.ru

Anatoly D. Shliapin¹, Doctor of Technical Sciences (habil.), Professor, Head of Materials’ Science Dpt., e-mail: 688412@mail.ru

¹ Moscow Polytechnic University  

The paper is devoted to the structure and phase composition of powders obtained by chemical dispersion of aluminum alloy with 20 wt % of silicon that studied after decanting and high-temperature synthesis in comparison with similar data for the alloy with 12 wt. % of silicon. The main crystal form of aluminum hydroxide  formed in the process of chemical dispersion of Al-20Si alloy is found to be gibbsite, as well as in the case of Al-12Si alloy. The synthesis conditions of the powders were determined using differential scanning calorimetry and thermogravimetry. After synthesis at 1000 °C no nepheline NaAlSiO4 is revealed in the powder made of Al-12Si alloy, it appears only in the run of high-temperature sintering and its amount reaches 25 wt %. At the same time in the powder made of Al-20Si alloy after synthesis at 1000 °C its content equals 100 %. The conclusion has been made about the need to clarify the dependence of the amount of nepheline in powder on silicon content in the alloy in the range of 12–20 % of silicon (e.g., 15 and 17 %). 

Keywords: aluminium alloy, aluminium oxide, nepheline, ceramics

References

1. Omarov А.Yu. Structure and properties of new materials produced from the waste of hydrogen oscillator operating cycle: dissertation of doctor science, Moscow 2010. Moscow State Industrial University.

2. Physicomechanical properties of ceramic materials prepared with chemical dispersion of aluminum alloy grade AK12 / A.D. Shlyapin, A.Yu. Omarov, V.P. Tarasovskii, Yu.G. Trifonov, A.I. Airikh // Refractories and Industrial Ceramics. 2013. Vol. 54. Issue 4. P. 288–290.

3. Ivanov D.A., Omarov A.Yu., Shlyapin A.D. Technology for processing the waste product obtained at the mobile hydrogen generator working cycle // Mechanical Engineering and Engineering Education. 2010. No 1. P. 31–36.

4. Shlyapin A.D., Ivanov D.A., Omarov A.Yu. Properties of aluminum alloy hydroxides obtained during production of hydrogen // Mechanical Engineering and Engineering Education. 2011. No 2. P. 48–51.

5. Studying the aluminum hydroxide powders obtained by aluminum chemical dispersion and its alloys /  A.D. Shlyapin, A.Yu. Omarov,  А.Kh. Khayri, Yu.G. Trifonov // New Refractory. 2012. No 10. P. 27–32.

Vladimir A. Petrov¹, Researcher of the Department of Aircraft Life Support Systems Dpt., e-mail:  petrovv@inbox.ru

Tatyana N. Gerasimenko², Doctor of Physic-Mathematic Sciences, Senior Researcher, e-mail:  staubchen03@gmail.com

Olga V. Kindeeva¹, Postgraduate Student of Aircraft Life Support Systems Dpt., e-mail:  ov.kindeeva@gmail.com

Aleksander I. Khaustov¹, Doctor of Technical Sciences (habil.), Professor, Professor of Aircraft Life Support Systems Dpt., e-mail: khaustov.alex@mail.ru

¹ Moscow Aviation Institute (MAI) (National Research University)

² BioKlinikum, Scietific-Technical Centre, JS Co. 

The article presents the results of the requirements analysis for micropump integrated into the microfluidic devices, which are used for cells culture. The materials that were biocompatible, elastic, strength, resistant to autoclaving, gas permeable, optical transparent have been chosen. Multiple experiments were conducted in order of chose the ratio of base/hardener, temperature and time modes of curing the polymer layer and enhancing the adhesion between structural elements. The technological process of manufacturing micropump integrated into the microfluidic device has been developed on the base of experiments. There were chosen optimum parameters for each of the three main stages of the technological process, which enabled to produce a quality product. 

Keywords: micropump, microfluidic device, polydimethylsiloxane, soft lithography

References

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12. Fincan M. Assessing Viscoelastic Properties of Polydimethylsiloxane (PDMS) Using Loading and Unloading of the Macroscopic Compression Test // PhD thesis, University of South Florida. 2015. Graduate Theses and Dissertations. URL: http://scholarcommons.usf.edu/etd/5480 (data of appl.: 12.05.2017).

13. Poly(dimethylsiloxane) thin films as biocompatible coatings for microfluidic devices: Cell culture and flow studies with glial cells / 
S.L. Peterson, A. McDonald, P.L. Gourley, D.Y. Sasaki // Journal of Biomedical Materials Research. 2005. Vol. 72A. No. 1. P. 10–18.

14. Leclerc E., Sakai Y., Fujii T. Cell Culture in 3-Dimensional Microfluidic Structure of PDMS (polydimethylsiloxane) // Biomedical Microdevices. 2003. Vol. 5. P. 109–114.

15. Skaalure S.C., Oppegard S.C., Eddington D.T. Characterization of sterilization techniques on a microfluidic oxygen delivery device // J. Undergrad Res. 2008. Vol. 2. No. 1. P. 1–4.

16. Mata A., Fleischman A.J., Roy S. Characterization of polydimethylsiloxane (PDMS) pro­perties for biomedical micro/nanosystems //Biomedical microdevices. 2005. Vol. 7. No. 4. P. 281–293.

Aleksandra I. Prokhorova¹, Doctor of Technical Sciences, Associate Professor of Materials’ Science Dpt., e-mail: prohorova-mami@mail.ru

Tatyana I. Balkova¹, Doctor of Technical Sciences, Associate Professor of Materials’ Science Dpt., e-mail: balkova.ti@yandex.ru

¹ Moscow Polytechnic University

The article presents the study results of the structure and properties of the punching tools surface layer made from steel Õ12M and reinforced by laser processing in different modes. The voltage of the pumping laser, changes the voltage of the pump laser, the degree of beam defocusing, the pulse repetition frequency and the degree of overlap of spots and tracks were being changed during processing. Laser treatment was performed with reflow of steel surface and without reflow. It is shown that in the case of laser treatment without surface melting, the die edge is blunted. Hardening of working edges must be carried out in a mode of microfusion. In this case, the laser exposure zone on all samples has a shape of a segment and consists of three layers: reflow zone, quench zone and tempering zone, which is transitional to a base metal. Thickness of a hardening zone is 40–45 μm and almost doesn’t depend on laser radiation energy.

Recommendations for strengthening the punching tools of complex shape were formulated. Results of tests presented a stable increase in durability of punching tools after laser thermostrengthening in 2–4 times.

Keywords: punching tool, laser treatment, hardening zone, micro-melting, structure, microhardness, die durability, surface layer

References

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11. Forming a Cr-Ni wear resistance coating with a specific high thermal stability by means of a combined laser-thermal processing / А.V. Makarov, N.N. Soboleva, I.Yu. Malygina, А.L. Osintseva // Physical Metallurgy and Heat Metal Treatment. 2015. No 3 (717). P. 39–46.

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13. The Behavior of Gas Powder Laser Clad NiCrBSi Coatings Under Contact Loading / R.A. Savrai, A.V. Makarov, N.N. Soboleva, I.Yu. Malygina, A.L. Osintseva // Journal of Materials Engineering and Performance. 2016. Vol. 25. No. 3. P. 1068–1075.

14. Alloying the Х12М steel surface at pulse laser emission treatment / V.S. Postnikov, S.А. Belova, Yu.N. Ivankin, М.N. Ignatov. URL: http://www.toolsru.com/docs/13-14/13-17.pdf (data: 25.12.2013).

15. Improving micromechanical properties and wear resistance of chromium-nickel laser alloy by finishing friction treatment / А.V. Makarov, N.N. Soboleva, R.А. Savray, I.Yu. Malygina // Vector of Science of TGU. 2015. No 4 (34). P. 60–67.

16. Characteristics of Ni-based coating layer formed by laser and plasma cladding processes / G. Xu, M. Kutsuna, Z. Liu, H. Zhang // Materials Science and Engineering A. 2006. Vol. 417. P. 63–72.

17. Abrasive wear behavior of laser clad and flame sprayed-melted NiCrBSi coatings / С. Navas, R. Colaco, J. De Damborenea, R. Vilar // Surface and Coatings Technology. 2006. Vol. 200. P. 6854–6862.

18. Microstructure and dry sliding wear behavior of laser clad Ni-based alloy coating with the addition of SiC / Q. Li, G.M. Song, Y.Z. Zhang, T.C. Lei, W.Z. Chen // Wear. 2003. Vol. 254. P. 222–229.

19. Magnetic Thickness Gauge МТ-101. Passport ПС-4276-006-52736667-04. М.: 2004. – 8 p.

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12. Usage of laser thermal processing for gradient materials creation on the base of Fe-Cr-Ni system / А.О. Andreev, М.P. Galkin, М.А. Libman, V.D. Mironov, V.N. Petrovsky, E.I. Estrin // Physical Metallurgy and Heat Metal Treatment. 2014. No 1 (703). P. 50–53.

13. The Behavior of Gas Powder Laser Clad NiCrBSi Coatings Under Contact Loading / R.A. Savrai, A.V. Makarov, N.N. Soboleva, I.Yu. Malygina, A.L. Osintseva // Journal of Materials Engineering and Performance. 2016. Vol. 25. No. 3. P. 1068–1075.

14. Alloying the Х12М steel surface at pulse laser emission treatment / V.S. Postnikov, S.А. Belova, Yu.N. Ivankin, М.N. Ignatov. URL: http://www.toolsru.com/docs/13-14/13-17.pdf (data: 25.12.2013).

15. Improving micromechanical properties and wear resistance of chromium-nickel laser alloy by finishing friction treatment / А.V. Makarov, N.N. Soboleva, R.А. Savray, I.Yu. Malygina // Vector of Science of TGU. 2015. No 4 (34). P. 60–67.

16. Characteristics of Ni-based coating layer formed by laser and plasma cladding processes / G. Xu, M. Kutsuna, Z. Liu, H. Zhang // Materials Science and Engineering A. 2006. Vol. 417. P. 63–72.

17. Abrasive wear behavior of laser clad and flame sprayed-melted NiCrBSi coatings / С. Navas, R. Colaco, J. De Damborenea, R. Vilar // Surface and Coatings Technology. 2006. Vol. 200. P. 6854–6862.

18. Microstructure and dry sliding wear behavior of laser clad Ni-based alloy coating with the addition of SiC / Q. Li, G.M. Song, Y.Z. Zhang, T.C. Lei, W.Z. Chen // Wear. 2003. Vol. 254. P. 222–229.

19. Magnetic Thickness Gauge МТ-101. Passport ПС-4276-006-52736667-04. М.: 2004. – 8 p.

Nikolay I. Smirnov¹, Doctor of Technical Sciences, Senior Researcher of the Friction Units for Extreme Conditions Laboratory, e-mail:  smir1947@yandex.ru

Anna N. Yagovkina¹, Engineer of the Laboratory of Tribological Processes Dynamics, e-mail: annyagovkina1@gmail.com

Maksim V. Prozhega¹, Doctor of Technical Sciences, Head of the Friction Units for Extreme Conditions Laboratory, e-mail:  prmaksim@gmail.com

Nikolay N. Smirnov ¹, Researcher of the Friction Units for Extreme Conditions Laboratory, e-mail: trenie12@yandex.ru

¹ Blagonravov Institute of Mechanical Engineering of the RAS

In the paper there are described the test bench of centrifugal type and test methodology for erosive wear of materials in model medium, which is an analog to formation fluid of oil well and containing water, abrasive particles, corrosive elements, is described. The test results for eight types of powder materials on the basis of iron and copper, alloyed by Ni, Cr, Mo and having ferrite-pearlite, pearlite or ferrite structure, in water with abrasive are presents. The parameters of experiment are: fluid jet velocity 11–16 m/s; attack angle 45°,90°; quartz and corundum particles of various dispersion F100, F40, F24 used as abrasive. The linear dependence of wear intensity on test time at various attack angles is revealed. Wear of powder materials in water by corundum particles of F100 size approximately five times higher, than with use of quartz particles of the same size. The “ПК90Н4МГ2КД15” material has maximum wear resistance at action of small particles of F100 size.

Keywords: erosive wear, centrifugal accelerator, powder materials, wear resistance

References

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Zhanat A. Daev  ¹, PhD, Doctor of Technical Sciences, Associate Professor, Head of Data Measuring Systems Laboratory, Technopark Zerek Partnership Ltd, e-mail:  zhand@yandex.ru

Ermek T. Nurushev², Postgraduate Student of the Department of Innovation and Integrated Quality Systems, e-mail: sunshine-13@mail.ru

1 Aktobe University named after S. Baishev

2 Saint Petersburg State University of Aerospace Instrumentation

The article raises questions of the transition of technical maintenance and organization of aircraft repairs from the traditional system, which is based on flights (in hours) to the operating system as per the state of the aircraft. Possible risks and their consequences in case of such a transition are discussed. The paper provides an overview of some methods of risk assessment. Therefore, the purpose of the article is to present the  application of combined methods for the failure mode and effect analysis (FMEA) and Shewhart control charts in order to reduce risks. The article shows the validity of the combined method application in the problem under consideration to ensure the airworthiness of aircraft. There are given recommendations on the calculation of control boundaries for Shewhart control charts. The proposed combined approach is not limited to use only in aviation enterprises and can be extended to many industries in order to reduce risks. 

Keywords: aviation, control, FMEA, Shewhart cards, risk, refusal

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