Prototyping of Straight Section Components Using Incremental Shape Rolling

Flexible Roll Forming (FRF) allows the forming of components with a variable cross-section along the length of the component. However, the process has only limited application in the automotive industry due to wrinkling in the flange which currently prevents the forming of high strength steels and limits the part shape complexity. This paper presents a new forming technology, Incremental Shape Rolling (ISR), where a pre-cut blank is clamped between two dies and then a single forming roll is used to incrementally form the material to the desired shape. The new process is similar to some Incremental Sheet Forming (ISF) approaches but with the difference that Incremental Shape Rolling (ISR) allows the manufacture of longitudinal components from high strength metal sheets. In this work, a numerical model of the ISR of a straight section is developed. Experimental prototyping trials are performed and are used to validate the numerical model which is then applied to analyse the new forming process. The results show that in ISR, tensile residual strains are developed in the flange. Flange wrinkling is observed and directly linked to the number of forming passes that are used in the process.

Installation for studying the parameters of localiInstallation for studying the parameters of localization of an electromagnetic wave in a waveguide of variable cross-section in the framework of the predictions of the 5-D extended space modelzation of an electromagnetic wave in a waveguide of variable cross-section in the framework of the predictions of the 5-D extended space model

The paper describes the creation and testing of an experimental setup for studying the parameters of localization of electromagnetic microwave radiation with a power of 0.001-0.004 W in the range of 36.0-79.0 GHz when propagating radiation in metal waveguides of variable cross-section. Measurements will also be carried out under conditions of filling the waveguide with dielectric materials with refractive indices from 1.46 to 4.0 for microwave radiation of the specified range. The installation is designed to measure the parameters of the localization of microwave radiation when it passes through a waveguide of variable cross-section, filled with materials with different refractive indices. Interpretation of the results will be carried out within the framework of the 5-D extended space model (ESM). The extended space model is formulated in (1+4)-dimensional space time-coordinate-interval. An additional spatial coordinate in the ESM is the interval. In the conjugate 5-D space, the energy-momentum-mass interval in the ESM corresponds to mass. In the ESM formalism, the question of the appearance of a nonzero variable mass in a photon and its localization under the influence of an external field is studied.

INTENSIFICATION AND STUDY OF HEAT TRANSFER AND FRICTION IN THE PLATE HEATING SURFACES OF THE KMS-2 AIR HEATER WITH A PRESSURE GRADIENT

A numerical study of heat transfer and friction in the heat exchanger channels in the presence of a variable pressure gradient is performed. The research was carried out in software complexes (Code_Saturne, Salome). The results of the validation of the research method are presented and they showed that the deviation of the numerical simulation results from the calculation data according to the known criterion equations is within the error of generalization of the experimental data by the criterion equations. According to the results of studies at Red=3000, Red=4177, Red=6000, it was found that the average value of the heat transfer coeffi cient of the channel of variable cross-section is up to 20 % higher than for the channel at dp/dx0. At the same time, the thermal-hydraulic effi ciency of the alternating channel (L=117 mm, l=58.5 mm, n=2) in the initial section at x =0...0.08 is lower than in the channel with dp/dx>0 by 26.7 %, and at x =0.08...1 it is higher by 5 ... 15 %, at dp/dx

Discrete-continuous three-element model of impact device

There have been examined the mathematic model of the impact device provided for geological materials destruction. Basic elements of the impact device are variable cross-section tool, striker and impact device body. The interaction of these elements is described as a movement of two discrete mass and the rod in the presence of rigid and dissipative connections. One equation in partial derivatives and two ordinary differential equations associated by initial and boundary conditions represent the initial-boundary problem. The numerical method parameters of which are determined at tests problems solution by Fourier method is used for looking for solutions of mixed initial-boundary problem. Researches are made, and parameters determining the damping efficiency of tool, striker and impact device body oscillations are evaluated.

Longitudinal-transverse thermal- force bending and stability layered inhomogeneous profiled rod

The solution to the problem of the stress-strain state of an inhomogeneous profiled rod is based on the use of nonlinear equilibrium conditions and physical relations of a layered thermo elastic thin rod. A differential equation of bifurcation inhomogeneous rod stability of variable cross-section is obtained. The equation has variable functional coefficients. In the initial state, the rod is subjected to bending with the implementation of one of the asymmetric shapes. The critical state occurs under the action of a longitudinal load corresponding to one of the lowest symmetrical shapes, orthogonal to the initial shape. In the first series, numerical calculations of an inhomogeneous I-rod with a variable cross section height are performed. Shelves and wall I-rod are made of steel, aluminum and titanium alloys. The graphs of maximum deflection and normal stresses acting at the calculate points at the boundaries of the layers are plotted depending on the longitudinal load at the given levels of transverse loads and thermal field. A significant influence of the rod physical structure, the profiling its form and the factor of nonlinearity of static relations on the stress fields has been established. A homogeneous temperature field with a nominal value of 80°C creates fields of self-balanced stresses in an inhomogeneous rod. The components of normal stresses in this case reach 20-40% of the materials permissible resistance level. The presence of rod parts with a significant difference in the coefficients of thermal expansion in the composition enhances this effect. In the second, the stability analysis of an inhomogeneous I-rod with a variable width cross section was performed. The transition of the initial S-shaped bend to an unstable state is shown.

Technological tests of a multi-seat device for vibro-shock processing of long parts of complex shape

The article deals with the issues related to the possibility of ensuring the indicators of quality of long complex-shaped parts by using vibration-impact processing in the technological process of their manufacturing using a special multi-seat device. The analysis of the design of representatives of long parts and the requirements for the quality of their surface layer, as well as the operational properties, made it possible to formulate the basic requirements for the design of multi-seat tools and develop a prototype for technological tests. The device allows processing two fragments of long parts and was used to establish the possibility of processing full-sized products and to establish optimal processing modes. Elements of the helicopter spars, which have the most complex design in the class of the considered parts, were used as fragments. Particular attention is paid to the processing of the inner surface of a complex shape and variable cross-section. The test results showed the possibility of using a multi-seat device for vibration-impact hardening treatment, which ensures the achievement of the specified parameters of the surface layer: surface roughness and microhardness with high process productivity.

FLOW OF WORKING MEDIA THROUGH THE CHANNELS IN THE BODY OF THE ELECTRODE-TOOL

Рассмотрен механизм течения жидких и газожидкостных рабочих сред через профильный инструмент для комбинированных методов обработки. Приведены типовые детали, для которых применимы электроды-инструменты с регулируемой подачей рабочей среды в зону обработки, обеспечивающей массовынос продуктов обработки из межэлектродного зазора. За счет применения аддитивных технологий решена проблема изготовления инструмента с внутренними каналами расчетного переменного сечения, обеспечивающими стабильную подачу жидкой (газожидкостной) среды и массовынос продуктов обработки. Предложены новые (на уровне изобретений) способ и электрод-инструмент с управляемой подачей по внутренним каналам рабочей среды, параметры которой рассчитаны с учетом специфики чистовой электроабразивной обработки по схеме копирования профиля детали. Расчетные зависимости для описания механизма течения рабочих сред и методы их использования позволили проектировать электроды-инструменты с профильными каналами, обеспечивающими применение технологических режимов для чистовой обработки инструментом с регулируемой подачей сред и выполнением критерия массовыноса продуктов обработки. Приведенные результаты расчета параметров течения рабочих сред через каналы в инструменте позволили расширить область эффективного использования аддитивных технологий и создать новые (на уровне изобретений) инструменты для электроабразивной обработки по методу копирования и высокопроизводительного одновременного профилирования нескольких поверхностей. Доказана возможность использования энергетической модели для расчета потенциальной составляющей энергии от реализации мощности, затрачиваемой на подкачку рабочей среды, и кинетической энергии от вращения инструмента для получения в зоне обработки требуемой скорости течения жидких (газожидкостных) сред We considered the mechanism of flow of liquid and gas-liquid working media through a profile tool for combined processing methods. We present typical parts for which electrodes-tools are applicable with an adjustable supply of the working medium to the processing zone, which ensures the mass removal of processing products from the interelectrode gap. Through the use of additive technologies, we solved the problem of making a tool with internal channels of a calculated variable cross-section, providing a stable supply of a liquid (gas-liquid) medium and mass removal of processing products. We propose a new (at the level of inventions) method and electrode-tool with a controlled feed through the internal channels of the working medium, the parameters of which are calculated taking into account the specifics of finishing electro-abrasive machining according to the pattern of copying the profile of the part. Calculated dependencies for describing the mechanism of flow of working media and methods of their use made it possible to design electrodes-tools with profile channels that ensure the use of technological modes for finishing with a tool with controlled supply of media and fulfillment of the criterion of mass removal of processing products. The presented results of calculating the parameters of the flow of working media through channels in the tool made it possible to expand the area of effective use of additive technologies and create new (at the level of inventions) tools for electro-abrasive processing using the copying method and high-performance simultaneous profiling of several surfaces. The possibility of using the energy model for calculating the potential component of energy from the implementation of the power spent on pumping the working medium and the kinetic energy from the rotation of the tool has been proved to obtain the required flow rate of liquid (gas-liquid) media in the processing zone