Edge-Tool Machining Efficiency Upgrading of the Hard-to-Machine Alloys by the Innovative Lubricating-and-Cooling Technological Means Application

Аuthors

Migranov M. S.^*, Metel’ A. S.^**, Repin D. S., Gusev A. S.

Moscow State University of Technology "STANKIN", 1, Vadkovsky lane, Moscow, 127994, Russia

*e-mail: migmars@mail.ru
**e-mail: a.metel@stankin.ru

Abstract

The growing need for domestic mechanical engineering and aircraft engine manufacturing continuous development is being be followed by the development and introduction into industry of the new brands of machined and tool materials with unique physical and mechanical properties and employed at high temperatures and under alternating loads. The required strength characteristics increasing herewith of the processed material for the critical parts of modern aircraft engines subjected to the edge-tool cutting leads to significant productivity degradation and its effectiveness as a whole, as well as increased consumption of the cost intensive carbide and tungsten-containing metal cutting tool. It is well-known therewith that the machine building industry progress depends for the most part on the volume and number of science-intensive developments for creating high-tech methods for the prospective aviation materials processing with innovative lubricating-and-cooling technological means (LCTM) application and subsequent capability of their effectiveness increasing by various physicotechnical means of their activation.
The article presents the results of theoretical-and-experimental studies of the developed innovative lubricating-and-cooling technological means with various oxygen-containing polymer additives, subsequently thermally activated while edge-tool cutting difficult-to-machine materials, such as heat-resistant, stainless chromium-nickel and titanium alloys, employed for critical parts of modern mechanisms and machines in aviation technology with the purpose of their operational functions efficiency improving. A series of wear resistance, temperature, and strength tests were performed herewith while longitudinal turning and drilling in a wide range of cutting conditions. Original designs of machine tools and means for controlling the main efficiency indicators of the blade cutting were developed to conduct full-scale experimental tests. The cutting tools wear resistance improvement was confirmed by the results of studying application specifics of the lubricating-and-cooling technological means with the state-of-the-art innovative oxygen-containing polymer additives while the edge-tool cutting. It allowed ensuring the productivity increasing with  quality indicators improving of the machined surface while the heat-resistant alloys lathing and drilling by the machinability. A positive effect of the use of oxygen-containing polymer additives on the basic machinability indicators when drilling difficult-to-machine metals has been established, with average torque reduction by 35%, as a parameter determining the cutting tools wear resistance and an average roughness reduction of the machined surface by 10%. All obtained results demonstrate a high degree of correlation between each other and the properties of the additives used. 
In general, based on the results of the research, the optimal compositions of LCTMs with oxygen-containing polymer additives and their rational modes of application have been determined and proposed. The widespread industrial applicatioin of these lubricating-and-cooling technological means in leading aviation enterprises will significantly increase the edge-tool cutting productivity of the difficult-to-machine materials, as well as significantly improve the machined surface quality compared to the traditionally applied basic LCTs, while ensuring improved sanitary and hygienic standards in the work zone of an enterprise. 

Keywords:

efficiency of critical parts of the aircraft power plants assemblies and units processing, innovative lubricating and cooling technological means (LCTM) with oxygen-containing polymer additives, thermo-activation effect of ionizer-ozonizerr on the LCTM, lathing and drilling heat-resistant chromium-nickel and titanium alloys, cutting tools wear resistance, cutting temperature at longitudinal turning, drilling torque

References

1.  Kolubaev AV, Kolubaev EA, Dmitriev AI, et al. Fundamental and applied aspects of materials science in tribology. Physical Mesomechanics. 2024;27(6):5-32. (In Russ.). DOI: 10.55652/1683-805X_2024_27_6_5-32
2.  Huang Q, Shi X, Xue Y, et al. Synergetic effects of biomimetic microtexture with multi-solid lubricants to improve tribological properties of AISI 4140 steel. Tribology International. 2022;167:107395. DOI: 10.1016/j.triboint.2021.107395
3.  Niu W, Yuan M, Wang P, et al. One-pot synthesis of SIB@ZIF-8 with enhanced anti-corrosion properties and excellent lubrication properties. Tribology International. 2020;151:106491. DOI: 10.1016/j.triboint.2020.106491
4.  Migranov MSh, Naumov AG, Repin DS, et al. Wear resistance of cutting tools with innovative multilayer coatings when using activated polymercontaining. lubricating-cooling technological means. Sborka v mashinostroenii, priborostroenii. 2023(6):271-275. (In Russ.). DOI: 10.36652/0202-3350-2023-24-6-271-275
5.  Repin DS, Naumov AG, Bubnov VB, et al. The metal cutting application aspects of materials which contain polymers and activated by corona discharge. Metalloobrabotka. 2022;127(1):3-10. (In Russ.). DOI: 10.25960/mo.2022.1.3
6.  Sultana MstN, Dhar NR, Zaman B. A review on different cooling/lubrication techniques in metal. American Journal of Mechanics and Applications. 2019;7(4):71-87. DOI: 10.11648/j.ajma.20190704.11
7.  Grigoriev SN. Cutting of materials. Cutting tool. Part 1. Moscow: Yurait; 2024. 263 p. (In Russ.). (In Russ.).
8.  Migranov MSh, Migranov AM, Mukhamadeev VR, et al. Application of static cool dry cutting in the cutting process. Vestnik UGATU. 2018;22(4):12-18. (In Russ.).
9.  Repin DS, Naumov AG, Bubnov VB, et al. Some results of the application of oxygen-containing polymer additives to lut activated by corona discharge in mechanical processing of metals by cutting. Pozharnaya i avariinaya bezopasnost'. 2022; 27(4):65-72. (In Russ.).
10.  Królczyk GM, Maruda R, Królczyk JB, et al. Ecological trends in machining as a key factor in sustainable production–A review. Journal of Cleaner Production. 2019;218:601-615. DOI: 10.1016/j.jclepro.2019.02.017
11.  Naumov AG, Komelkov VA, Emchenko DV, et al. The influence of micro-doses of iodine, as a component of SOTS when processing metals by cutting. Sovremennye problemy grazhdanskoi zashchity. 2020(2):78-85. (In Russ.).
12.  Ross NS, Mia M, Anwar S, et al. A hybrid approach of cooling lubrication for sustainable and optimized machining of Ni-based industrial alloy. Journal of Cleaner Production. 2021;321(3):128987. DOI: 10.1016/j.jclepro.2021.128987
13.  Damdinov BB, Mitypov ChM. Studies of the Coefficient of Friction. Derivation of the Analytical Equation of the Hersey- Shtribek Diagram. Journal of Siberian Federal University. Engineering & Technologies. 2022;15(7):835–849. (In Russ.). DOI: 10.17516/1999-494X-0439
14.  Park KH, Suhaimi MA, Yang GD, et al. Milling of titanium alloy with cryogenic cooling and minimum quantity lubrication (MQL). International Journal of Precision Engineering and Manufacturing. 2017;18(1):5-14. DOI: 10.1007/s12541-017-0001-z
15.  Wang X., Zhang X., Wang C., et al. High temperature tribology behavior of silicon and nitrogen doped hydrogenated diamond-like carbon (DLC) coatings. Tribology International. 2022;175:107845. DOI: 10.1016/j.triboint.2022.107845
16.  Nikitin KA, Mordus NA, Evstratenko MV. Analysis of the effect of cryogenic treatment on the performance of cutting tools. VIII Mezhdunarodnoi nauchno-prakticheskoi konferentsii “Innovatsionnye tekhnologii v agropromyshlennom komplekse - segodnya i zavtra” (November 15, 2024; Gomel, Republic of Belarus). Gomel: Gomsel'mash, 2024. Part 1. p. 211-214. (In Russ.).
17.  Kozochkin MP, Porvatov AN. The development of portable and integrated diagnostic system for the analysis of processes of cutting materials. Kontrol'. Diagnostika. 2017(1):44-48. (In Russ.). DOI: 10.14489/td.2017.01.pp.044-048
18.  Kozochkin MP, Porvatov AN, Duisengali A. Adaptive control system for machine tools based on vibration and active power signals. Avtomatizatsiya i upravlenie v mashinostroenii. 2016(1):17-25. (In Russ.).
19.  Pogonyshev VA, Pogonysheva DA. Artificial intelligence as a tool of modern tribology. Materialy II Mezhdunarodnoi nauchno-prakticheskoi konferentsii “Sovremennye tendentsii razvitiya agrarnoi nauki” (December 07-08, 2023; Bryansk). Bryansk: BGAU; 2023. p. 479-485. (In Russ.).
20.  Sovetkanov A, Shayakhmetov Ye, Meirbekov R. Refinement of the parametric model of roughness formation by conducting an experiment. Bulletin of Shakarim University. Technical Sciences. 2024;1(13):62-72. (In Kazakh). DOI: 10.53360/2788-7995-2024-1(13)-9
21.  Syrbu SA, Naumov AG, Kolbashov MA. Method of preliminary assessment of the effectiveness of a lubricant in the contact zone of tribo-conjugated metal surfaces. Materialy XV Mezhdunarodnoi nauchno-tekhnicheskoi konferentsii “Tribologiya - mashinostroeniyu” (November 12-13, 2024; Moscow). Moscow: IMASH RAS; 2024. p. 209-211. (In Russ.).
22.  Savel’eva LV, Vendin IO. Cutting conditions effect on tool front surface wear rate while workpieces machining. Aerospace MAI Journal. 2019;26(4):209-215. (In Russ.). DOI: 10.34759/vst-2019-4-209-215.