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Journal "Vestnik BSTU" 5 (58) 2017

Founder is the federal State budgetary
Educational Institution Higher Professional
Education "Bryansk State Technical University"

Chairman of Editorial Council O.N. Fedonin, D.Eng., Prof.

Vice-Chairman of Editorial Council E.A. Pamfilov, D.Eng., Prof

Editorial Council:
A.A. Abramov, D.Eng., Prof., (Moscow)
V.I. Averchenkov, D.Eng., Prof., (Bryansk)
E.V. Ageev, D.Eng., Prof., (Kursk)
A.Yu. Albagachiev, D.Eng., Prof., (Moscow)
V.Yu. Antsev, D.Eng., Prof., (Tula)
A.P. Babichev, D.Eng., Prof., (Rostov-upon-Don)
V.F. Bezyazychny, D.Eng., Prof., (Rybinsk)
A. Bukhach, D.Eng., Prof., (Poland)
I. A. Buyanovsky, D.Eng., Prof., (Moscow)
L.G. Vainer, D.Eng., Assistant Prof., (Khabarovsk)
G.M. Volokhov, D.Eng., Prof., (Kolomna)
O.A. Gorlenko, D.Eng., Prof., (Bryansk)
S.V. Davydov, D.Eng., Prof., (Bryansk)
A. A. Dyakonov , D.Eng., Prof., (Chelyabinsk)
A.G. Ivakhnenko, D.Eng., Prof., (Kursk)
S.A. Klimenko, D.Eng., Prof., (Ukraine)
V.V.Kobishchanov, D.Eng., Prof., (Bryansk)
I.S. Konstantinov, D.Eng., Prof., (Belgorod)
A.S. Kosmodamianskiy, D.Eng., Prof., (Moscow)
K.V. Makarenko, D.Eng., Prof., (Bryansk)
B.Ya. Mokritsky, D.Eng., Prof., (Komsomolsk-upon Amur)
A. Pester, D.Eng., Prof., (Austria)
D.I. Petreshin, D.Eng., Prof., (Bryansk)
V.B. Protasiev, D.Eng., Prof., (Tula)
L.A. Savin, D.Eng., Prof., (Orel)
V.P. Smolentsev, D.Eng., Prof., (Voronezh)
D.L. Solovyov, D.Eng., Prof., (Murom)
Yu.S. Stepanov, D.Eng., Prof., (Orel)
A.G. Suslov, D.Eng., Prof., (Bryansk)
A.V. Khandozhko, D.Eng., Prof., (Bryansk)
M.L. Kheifits, D.Eng., Prof., (Belarus)
S.N. Khimukhin, D.Eng., Prof., (Khabarovsk )
A.S. Yanyushkin, D.Eng., Prof., (Bratsk)

Editorial board:

Editor-in-chief
A.V. Kirichek, D.Eng., Prof.

Deputy editor-in-chief
A.V. Morozova, Can.Sociol. Sc.

Executive secretary
V.A. Tatarintsev, Can.Eng.

Proof-reader V.A. Yerokhina

Editor M.L. Shcherbakova

Registration certificate
by Federal Service for Supervision of Legislation
in Mass Media and the protection of cultural heritage
PI FS77-21709 August 17, 2005

Address editorial office:
7, Bulvar 50-letiya Oktyabrya,
Bryansk, 241035, Russian Federation
tel. (4832) 58-82-77
e - mail: vestnik@tu-bryansk.ru

The subscription index of catalogue
Russia press - 18945 semi-annual,
15621 annual.

It is issued in February 2004.
4 numbers a year

CONTENTS

Mechanical engineering and engineering science

M.V. Zernin, N.N. Rybkin. EFFICIENT ORGANIZATION ALGORITHMS OF INTERCONNECTIONS OF ELASTIC AND HYDRODYNAMIC CONSTITUENTS OF FINITE ELEMENT SIMULATION OF FRICTION UNIT ELASTIC HYDRODYNAMICS
Basic algorithms decreasing labor intensity in the solution of a problem connected with elastic hydrody-namics are formulated. Some options for the formation of cost-effective grids of finite elements are presented. It is shown the efficient use of the method of condensation in order that in a non-linear procedure only the units lo-cated on operation surfaces of a friction unit should be considered. A cost-effective option for the realization of a condensation method is described in a short way. The algorithm of the reduction of pressures distributed on a surface to the system of concentrated unit loads is stated thoroughly. The computation algorithm of points dis-placements of a surface in the direction perpendicular to it is shown
Key words: elastic hydrodynamics problems, elastic deformations, hydrodynamic pressures, finite element method, grid concentration, reduction method, condensation method, approximating polynomial

A.F. Denisenko, M.V. Yakimov. TEMPERATURE IMPACT OF SPINDLE UNIT BEARING UPON ITS STIFFNESS
The paper reports the interconnection between the stiffness of a lathe spindle unit bearing and its tem-perature deformations. A full-scale experiment for the impact assessment of the processes connected with lathe heating upon radial stiffness anisotropy of the spindle unit front bearing of on-line NC SAMAT-400SC Vector lathe is carried out. An elastic defor-mation dependence of spindle unit front bearing upon loading at heating for different directions is defined. The analysis of experimental data has shown that the anisotropy of spindle unit elements increases at heating and at the radial load increase; for a heated lathe a locus has no pronounced fractures and gets a regular form approaching ellipse. A computation of tempera-ture deformations in the front wall of the headstock of the lathe mentioned is carried out through the finite element method. The analysis of the form of tempera-ture deformations of headstock body boring made it clear that a bearing bore obtains a deviation from circularity as an irregular ellipse. The results of the numerical experiment allowed substantiating the anisotropy presence of bearing stiffness at its heating and its orientation obtained during the full-scale experiment. The investigations carried out have shown that at lathe heating the anisotropy of spindle bearing stiffness formed at manufacturing and lathe assemblage increases, but bears a clearly directed character
Key words: spindle unit bearing, temperature deformations, anisotropy, stiffness, radial load

N.D. Feofilov, E.S. Yanov, A.S. Yamnikov. DEVICES FOR SAMPLE FASTENING DURING EXPERIMENTAL INVESTIGATIONS
The paper reports the consideration of problems connected with design peculiarities of devices for sam-ple fastening on gear-milling machines during the in-vestigation fulfillment of a gear milling process of cy-lindrical wheels with combined hob milling cutters. The essence of the problem is reduced to that the ful-fillment of investigations directed to the definition of a hob durability term and also of the modes and a force of cutting upon real large cog-wheels is not always possible as on domestic engineering enterprises they are manufactured mostly with small-lot or limited produc-tion and their price is high. Therefore, it is offered to substitute expensive and long experiments for exper-iments with special samples. In the paper there are de-scribed designs and circuits of the installation of the devices developed for such samples. In conclusion there are shown test results and is made a conclusion of that the use of the devices offered allowed defining and correcting tool parameters, cutting modes, defining a tool durability period at the stage of technological pre-production of manufacturing large cog-wheels made of hardened steel
Key words: experiment, combined hob milling cutter, toothed rack, device, design, sample

S.V. Khodyrevskaya, A.A. Gorokhov, O.G. Kuts, Yu. A. Malneva. CUTTING EDGE ANALYTICAL DESCRIPTION OF REPLACEABLE INDEXABLE INSERTS OF COMPOUND FORM CUTTERS
The formation of the efficient methods for as-sessed parameters computation is impossible without a mathematical description of cutting edges of replacea-ble indexable inserts (RII), its front surface and an end flank. The most expedient way is supposed to be the fulfillment of an analytical description of RII cutting edges by means of the vector functions set: by the function of cutting edge radius-vector; by the function of the vector of normal to a front surface: by the func-tion of the vector of normal to an end flank. The given description was considered by the example of some forms and plates formation (according to SRS 19042-80) used in the designs of compound form cutters, to wit: of equilateral and equiangular inserts with a radius at the tops; round; rhombic; triangular with faces at the tops. The realization of the given functions in Maple system allowed carrying out the simulation and a geometrical presentation of cutting edges of the RIIs under consideration. The analysis of the results obtained allowed drawing a conclusion of the adequacy of functions obtained which makes it possible to use them at the creation and development of CAD/CAM systems of compound form cutters
Key words: : replaceable indexable inserts, compound form cutters, model of a cutting edge

S.Yu. Syanov. DEVELOPMENT OF FUNCTIONALLY-ORIENTED TECHNOLOGICAL PROCESS OF ELECTRICAL DISCHARGE MACHINING
Describes the development of functionally-oriented technological process of electrical discharge machining. Functionally-oriented technological processes belong to a special thin, accurate and science-intensive technologies, which provide complete adaptation of the product to the features of its operation. Describes the stages of development of functionally-oriented technological process of electrical discharge machining from the allocation of the surfaces of the parts and their functions to determine the process parameters of electric erosion, which will ensure not only the quality parameters of the surface layer, but also the required performance properties
Key words: functionally-oriented technological process, electrical discharge machining, the quality of the surface layer, the operational properties of machine parts

A.P. Shishkina, V.A. Lebedev, M.M. Chaava. ENERGY ASPECTS OF PARTS VIBRATING PROCESSING WITH KERNEL ORGANIC ENVIRONMENT
This paper reports the fulfilled analysis of ap-proaches to the simulation of the processes of a vibra-tion treatment with granulated media. A model of the vibration treatment process ensuring an efficient finish-ing of parts surfaces with granules of kernel organic media is developed the basis of which is formed by the approach based on an energetic impact of a granule flow upon the surface under treatment. As a basic characteristic of the process of the organic media treatment a specific volume metal removal is used a physical sense of which consists in the velocity of a thickness growth of material removed from the surface at specified velocity and medium pressure. It is shown that metal removal depends upon the velocity of medium flow, the height of a loading column of granulated medium and conditions of the formation of a medium stationary circulating motion. On the basis of the analysis of experimental investigations results of amplitude-frequency characteristics influence upon metal removal during the vibrating processing with abrasive granules the dependence of a specific volume metal removal is offered at the treatment with organic media, taking into account a threshold amplitude and oscillation frequency of the working chamber at which the effect of a surface treatment is observed. The defined aggregate of dependences, describing the efficient conditions of vibrating processing with kernel organic media, is obtained with the application of experimental data which allows supposing the reasonableness of the model obtained
Key words: vibrating processing, kernel organic medium, specific metal removal, environment pressure, threshold amplitude of oscillations, threshold frequency of oscillations, loading height, surface finishing

B.Ya. Mokritsky, A.V. Morozova, Ya.V. Konyukhova, E.B. Mokritskaya. PECULIARITIES IN REDUCTION TREATMENT OF RAILROAD CAR WHEELS
The problems of wheel-turning reduction treat-ment are connected with both a large quantity of wheels under treatment, and with a large amount of material removed from the surface of wheel tread in connection with defects arisen during the car operation. In the course of the wheel reduction treatment the con-tinuous chip is formed, which is traumatic and difficult for removal and transportation. The well-known solutions on chip crushing for wheel turning have a special character and are carried out at the expense of the cutting face complex geome-try of cutter plates. At present the production of domestic competitive cutter plates is not carried out, which makes one of the urgent problems for recovery production the solution of which is based on import substitution of the equipment operated. The purpose of this work consists in chip break-ing efficiency increase without decrease of productivity and quality of the reduction treatment of railroad car wheels. To achieve the purpose the methods of the me-chanics of solid deformation are used allowing the op-timization of the cutting face topography of the tangential cutter plate. Power, supplied for cutting with the developed plates, is lesser of that essential for cutting with Pramet plates used at present in recovery production which witnesses the formation of more favorable cutting conditions and lesser values of a cutting force. Plate tests have shown positive results
Key words: reduction treatment, wheel, railroad car, chip breaking, operational defect

V.P. Tikhomirov, A.O. Gorlenko, M.A. Izmerov, A.N. Yerokhin. MODELING OF CONTACT INTERACTION OF SPHERICAL SURFACES OF BEARINGS OF SLIDING
TThe solution of contact problems taking into ac-count surface micro-geometry entailed certain difficul-ties: a surface roughness has a complex structure hav-ing a random component, but for all that it affects considerably a conjugation load capacity. The account of the impact of a rough surface with different factors results in a substantial distortion of the result. In addi-tion at the stage of distortion design an engineer is not aware initially of the quality of future surfaces which are to be matched for the best result. The procedure presented in this work allows ful-filling a computation of a spherical plain bearing taking into account the impact of conjugated surfaces roughness. The problem is solved through the simulation of a rough layer with the aid of the formation of fractal 3D models and parameter definition of the contact of a smooth ball with a half-space at the presence of roughness with equivalent parameters. A rough layer at that is as a 3D continuous coating with fractal geometry equivalent to a real surface and with a variable coefficient of elasticity depending upon a fractal dimensionality and degree of coating deformation. It allows increasing considerably the computation accuracy, automating and acce-lerating a designing process
Key words: spherical plain bearing, static load capacity, surfaces contact, fractal dimensionality, simulation, de-formation

Informatics, computer engineering and management

P.A. Akulov, D.I. Petreshin. AUTOMATED PLANT FOR MEASUREMENT OF JOINT ANS DISJOINT FORCE OF ELECTRIC CONNECTOR SINGL CONTACT
At present in industry the whole process of as-sembling and tests of electric connectors is carried out manually. Such processes, on the one hand, lead to rise in price of products caused by inefficient use of man-power reserves, and on the other hand, do not exclude a moment of a so-called human factor. The purpose of this work is an increase of productivity and accuracy of the measurement of joint and disjoint forces of contacts in electric connectors at the expense of mea-surement process automation. We have an electric connector in which it is necessary to determine a joint and disjoint force of the contact by means of the input reply part (pin) of the connector with the fixation of measurement results, storage and retention for the further analysis. In the structure of the automated plant for the joint and disjoint force measurement of electric connector contacts there are following units: a measurement units, a unit for symbolic information mapping, a unit for drive control of the measurement plant. The measurement time of a joint and disjoint force for one contact makes 1.5 2s, joint-disjoint rate 10 mm/s. The developed automated plant for the meas-urement of a joint and disjoint force of the electric connector single contact and realized as a prototype has shown its working capacity. An error in the defini-tion of a joint and disjoint force of an electric con-nector single contact made 0.01 N. The data obtained are new and of a certain interest at the production quality assessment of electric connector contacts
Key words: force measurement, contact joint, contact disjoint, automated measuring apparatus, single contact

Metallurgy and materials science

A.F. Balaev. SUPERSONIC RELAXATION INVESTIGATION OF METAL PLATE RESIDUAL STRESSES BASED ON CAD
For the stabilization of elastic plate geometric parameters in the production there is used a method of training having low productivity as an alternative to which a method of supersonic stabilization is devel-oped. The essence of a supersonic stabilization consists in the creation of elastic deformation applied by a static load in the central area of the plate and in imparting a tool supersonic oscillations which results in the relaxation of residual stresses and the stabilization of plate geometrical parameters. For the technological parameters computation of a supersonic treatment there are obtained analytical expressions. The computer simulation carried out on the basis of computation-analytical models allowed revealing and presenting vividly the dependences of residual stresses and a plate deformation upon duration and amplitude of ultrasonic oscillations. On the basis of the dependences obtained it is defined that for the value decrease of a residual deformation the amplitude of oscillations should be decreased, but at the same time the processing period increases. At that, the larger the amplitude of oscillations, the more intensive the decrease of residual stresses occurs. The intensive change of a residual deformation and stresses during the initial some seconds characterizes a high productivity of an ultrasonic stabilization recommended as a substitution of the training technology
Key words: supersonic relaxation, deformation, residual stresses, CAD, plate

Transportation means

E.V. Slivinsky, V.I. Kiselyov. UNDERCARRIAGE MODERNIZATION OF DIESEL LOCOMOTIVE TEP60
It is well-known, that during the motion of lo-comotives on curved areas of a track one observes an increased wear of flanges in wheel pairs. It is a consid-erable drawback of three-axle bogies of locomotives. To eliminate such a drawback in Bunin ESU is devel-oped at the invention level a promising design of a three-axle bogie of a locomotive having increased op-eration reliability at the expense of the use of a promis-ing RUKP design
Key words: propulsion electromotor, wheel pair, lever, spring suspension

A.I. Komarov, A.V. Vdovin, A.L. Zabelin. TECHNOLOGY DEVELOPMENT FOR BUSHES REBUILDING OF CRANKSHAFT- AND CRANKPIN BEARINGS FOR CRANKSHAFT OF ENGINE D-355C KOMATSU
The problems in rebuilding parts of imported architectural engineering are considered. The results of the technology development for rebuilding bushes of crankshaft- and crankpin bearings of a crankshaft for the engine D-355 Komatsu are shown. The analysis of the destruction character of crankpin bearing bushes is presented. A rebuilding technology for bushes by means of applying babbit B88 with arc spraying is de-veloped. The parameters of an arc spraying mode are developed and shown
Key words: rebuilding, bushes of crankpin bearings, babbit, arc spraying

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