Abstract: 433 Diagnostics of cutting tools and prediction of their remaining life must be regarded as a priority in numer ically controlled systems, where the operator does not intervene in the process, which must be completed without fracture and replacement of the tool [1, 2]. The problem is that, even within a single batch, tool life may vary widely (by 15–35%). If the life is deter mined on the basis of the worst tool in the batch, the most durable tools will utilize only 65% of their avail able life; that clearly results in unnecessary expendi tures on tool replacement [3].

Abstract: The production of powder by rotary grinding is considered. A mathematical model is developed, as well as an appropriate tool design.

Abstract: The geometric characteristics of the machined sur� face of a blank (slab) are mainly determined by the motion of the cutting system's components, which depend on the external dynamic forces due to the machining process. A key factor here is the highspeed spindle of the metalcutting machine, on which the tool is mounted. The spatial motion of the spindle's axis will depend on the structural imbalances of the mill, noncoaxiality of the mill and spindle after attach� ment, imbalances of the spindle, and changes in the cutting force due to the unstable properties and vari� able margin of the blank. The spindle is mounted in bearings 1 and 2 (Fig. 1a) and supports a complex mill 3 (by cantilever attachment). Longitudinal slots in mill 3 accommo� date cutting plates 4, made of tool material. Cutting plates 4 remove surface layer 7 and knots 5 randomly distributed in the material (Fig. 1b). The machined material of slab 6 is nonuniform, with variation in the hardness, the density, and the margin. The external working load on the cutting system consists of the cutting force, the unbalanced centrifu� gal force due to primary imbalance vector Dst of the spindle, and the bending torque M of the pair of iner� tial unbalanced centrifugal forces P1-P1 due to the presence of primary imbalance torque MD in the spin� dle. The increments in the cuttingforce components P z and P y are due to machining of the knots within the slab. In addition to these increments, an axial compo� nent P i appears in machining the knots. By x 1 , y 1 , x 2 , y2, respectively, we denote small displacements in the first and second bearings in the direction of the X and Y axes, with vibration of the mill's spindle in machining.

Abstract: 57 The vibrational displacement of the machine tool, the attachment, the tool, and the blank affects the pro ductivity in machining, as well as the geometric preci sion, size, roughness, and undulation of the machined surface and the life of the equipment. These output parameters of the machining process are important not only for the production of metallic components but also for plastic, wood, and other materials. The creation of machining processes characterized by minimal vibration calls for methods of reducing and suppressing the vibration.

Abstract: The cutting of channels in quenched-steel components is considered. A relation is established between the cutting parameters and the operational characteristics of tools with ceramic cutting plates.

Abstract: Diffusional processes in the cutting of high-alloy steel by means of a hard-alloy tool are considered. At the front surface of the tool, a carbide coating may be formed on cutting, on the basis of carbide-forming elements in the steel and carbon diffusing from the hard alloy. Reactive diffusion without the formation of visible intermediate layers is assumed to affect tool wear.

Abstract: In the modular approach, all the surfaces of machine parts are divided into three classes of surface modules: basing surface modules; working surface modules; and coupling surface modules [1]. Representing machine parts as sets of surface mod� ules permits the design of the manufacturing process by combining machining modules. That entails the creation of a bank of machining modules. Working surface modules are characterized by a great diversity of designs and quality requirements, on account of their wide range of functions. Correspond� ingly, we need the corresponding machining modules. Working surface modules include sets of frictional surfaces (bearings, guides, etc.); contact surfaces of kinematic elements (working surfaces of gear teeth and racks, cam surfaces, etc.); combinations of cutting surfaces (cutters, mills, countersinks, etc.); sets of working surfaces for dies; contact surfaces of rails and wheels; and combinations of surfaces for the storage of powders, liquids, and other media. The composition and geometry of working surface modules, as well as the corresponding quality require� ments, will be determined by the processes in which they are involved. With the same surface composition and geometry, the quality requirements will depend on the intended functions. Therefore, for the same struc� ture of working surface modules, different machining modules may be required.

Abstract: (Fig. 1a). The shaft is produced fromround hardalloy rods with a crescentshaped aperture(Fig. 1b). The rods are manufactured by die pressingfrom singlecarbide hard alloys containing 6–10%carbide binder; the grain size of the tungsten carbide is0.5–1.3 μm. Such alloys are characterized by highelastic modulus and flexural strength:

Abstract: The stress-strain state of prismatic samples with stress concentrators (hollow chamfers) is analyzed by numerical simulation.

Abstract: The critical cut thickness is determined in planing various materials. With greater thickness, the use of lubricant and coolant fluid reduces the cutting forces. Therefore, with limited rigidity of the technological system, the use of lubricant and coolant fluid is only expedient at above-critical cut thickness.

Abstract: The selection of the basic characteristics of any pri� mary drive relies on the analysis of the technological operations to be performed on the new system [3, 4]. We must identify the machining processes for the set of standard surfaces that constitutes the representative (notional) part. In the analysis, the following parame� ters are varied: the material of the blank and cutting tool, the type of tool, the type of treatment (roughing or finishing), and the cutting conditions (speed, depth, supply). This is necessary to identify the limit� ing spindle speeds (maximum nmax and minimum nmin), the working supplies, and the maximum power Pn, torque Mn, and force Fτmax. Analysis permits estimation of the form and limit� ing (maximum and minimum) dimensions of the basic and auxiliary tool, for subsequent selection of the cou� pling between the spindle and the tool mandrel. The machining of a representative part permits the selec� tion of the bearing life for the spindle on the basis of the cutting forces, the speed, and the times of surface treatment [5]. In a multivariant solution, we consider several pos� sible parameter combinations. The combination with the maximum productivity and efficiency of tool use is selected. The productivity in roughing and finishing is assessed on the basis of the cutting productivity Q (the volume of material removed from the blank) and the shaping productivity Ssh (the area of the machined sur� face removed per unit time).

Abstract: A model for the margin removal and grinding forces in bidirectional machining of the ends of a single blank is proposed. The dependence of the margin removal on the reduced rigidity of the machine tool’s elastic system and the grinding conditions is considered.

Abstract: The working element of the attachment is a dia mond tip 1, receiving the force from calibrated spring 3 in housing 2. By means of handle 4, the attachment is mounted in the cutter holder of a lathe. All the attachments are based on a spring mechanism. The force required for diamond smoothing is provided by compression of the spring using screw 5, whose dis placement is monitored by means of a scale on the housing. Natural and synthetic diamond tips are used for smoothing. The selected radius of the diamond sphere is 0.5–4 mm, depending on the initial hardness of the surface to be smoothed.

Abstract: A method is proposed for increasing the stability of a constant-speed hydromechanical system developed for ground transportation. The method is based on a dynamic shock absorber in a centrifugal pendulum.

Abstract: Manufacturing processes for complex components with longitudinal fins and a collar are described.