ISSN 2414-3820 , , 2016, . 46 258 . . , . . , . . ( ). - 4416576/31-27; . 28.04.88; . 30.01.90, . 4. 16. . . 1712031 , . . 21 D 28/14. [ ] / . . , . . , . . , . . ( ). - 4708457/27; . 22.06.89; . 15.02.92, . 6. 17. . . 1696320 , . . 30 15/28. [ ] / . . , . . , . . ( ). - 4746073/27; . 06.10.89; . 07.12.91, . 45. Vladimir Mirzak, Sr. Lect.,Viktor Bokov, Prof.,PhD tech. sci. Kirovohrad National Technical University, Kropivnitskiy, Ukraine The principle of dynamic adjustment as a means of thin-sheet dividing stamping quality increase The purpose of the research is thin-sheet dividing stamping quality increase due to the application of dynamic adjustment principle. The quality of thin-sheet dividing stamping is determined first of all by the “press-stamp” system state, namely it depends on the loaded stamp detail deformation degree, as the given system is a source of nearly 60 per cent of errors which influence the loss of quality. The main idea of the paper is the possibility to significantly improve the quality increase of thin-sheet dividing stamping due to the application of the offered principle of dynamic adjustment. Stamping is done with dynamic adjustment of the “press-stamp” system in the direction of the coincidence of the press technological effort application axis with the axis that goes through stamp pressure centre. The quality increase is reached due to unloading the guide units of radial efforts and significant deformation decrease of stamp parts. The offered mechanical compensators that realize the given principle demonstrated significant improvement of stamping quality (lifting up decrease, dimension deviation scale, etc). dynamic adjustment, mechanical compensator, dividing stamping quality, thin-sheet stamping 21.04.16 621.891.539.375.6 Mykhailo Chernovol, Prof., DSc., Igor Shepelenko, Assoc. Prof., PhD tech. sci., Budar Mohamed R.F., post-graduate Kirovohrad National Technical University, Kropivnitskiy, Ukraine E-mail: ivsepelenko@mail.ru Appliances for FANT of cylinder liners Despite the successes achieved in practical application of FANT of cylinder liners there is no wide application of the technology because of low productivity and processing quality which may be increased by the use of new schemes of FANT and improved tools for finishing. The article presents the analysis of the existing appliances for FANT of cylinder liners and the ways to improve their design were specified. That will increase the productivity and quality of treatment as well as the effectiveness of FANT application. finishing antifriction nonabrasive treatment, appliance, cylinder liner, antifriction coating, combined treatment ___________ © Mykhailo Chernovol, Igor Shepelenko, Budar Mohamed R.F., 2016 ISSN 2414-3820 , , 2016, . 46 259 . . , ., - . , . . , ., . . , . ., . , . , , , , . , , , . , , , , Problem description. It was proved by many studies that finishing antifriction nonabrasive treatment (FANT) of cylinder liners has economic advantages compared to the traditional ways of treatment [1-8 and others]. It allows decreasing the time of engine run-in and, therefore, decreasing the consumption of fuels and lubricants and to increase engines life time and its reliability. At the same time, the applied FANT technologies are characterized by low productivity, uneven layer of coating, high loads on tools, significant heat liberation and the necessity of further hardening of the surface layer. It is possible to increase the productivity and quality of the treatment by application of new technologies and schemes of implementing FANT [9], development of tools that will rectify the above-mentioned problems [10], usage of modern materials and effective technological environment for the frictional coating process [11]. Objective of research. The objective of the work is to analyse the existent structures of the appliances for FANT of cylinder liners with further elaboration of recommendations for their improvement. Research results. Application of FANT demands the usage of positioning and rotator devices, for example turning machine, polishing or boring machine with the polishing device fixed in the tool holder [1]. The difference of sizes and configurations of the parts to be coated determines the application of various ways of FANT and appliances for implementation of the work. The simplest scheme of FANT of the bushing is presented in Picture 1 [2]. The appliance 4 with brass rod 3 is fixed on the drilling rod 5, which is fixed in tool holder 6 of the turning machine. In the process of brassing the brass rod is pressed to the surface of bushing 2 with force corresponding to the pressure of 70 Pa, and is moved along the bushing with 0,2 mm/rev. The bushing fixed in the chuck of the turning machine rotates with peripheral velocity of 0,3 /s. The fluid which consists of glycerin and activator is delivered to the area of brassing by a dropper. 654321 1 – turning chuck; 2 - bushing; 3 – brass rod; 4 - appliance; 5 – drilling rod; 6 – holder of turning machine Picture 1 – Scheme of frictional brassing of bushing ISSN 2414-3820 , , 2016, . 46 260 These types of appliances have significant demerits that are low productivity, uneven coating and as a result a considerable surface undulation. The German scientific school elaborated a number of appliances for FANT of engine cylinders [3]. The appliances are designed in such a way that their polishing core (tool) revolves round its axis. That allows providing [4]: - in-line contact of the element including its small area with the surface under polishing. This enables to have high pressure under small pressing force; - constant change in the area of the contact in the process of FANT. So, it was specified [3-4], that the maximum hardening of the steel and pig iron surfaces happens when there is an in-line contact between the tool and the part under treatment. There is another example of liners treatment in metal plaque lubricant where buffing wheels are mounted on the honing head and are used as the tool [5]. The appliances on the basis of the honing machine with application of special honing head which has abrasive and antifriction sticks can be used for FANT of cylinder liners [6-8]. In work [5] the attention is drawn to the practicability of making a tool for FANT on the basis of the honing head which provides its centering relatively to the treated hole. The author recommends using brass L62 or L63 as the material for the polishing element. A higher content of brass is not desirable as it results on plastic features of the material. The appliance for FANT of cylinder faces in metal plaque lubricants was elaborated which shown in Picture 2 [12]. 1 6 15 912138 14 11 7 10 2 3 4 5 1 – housing; 2 – drive shaft; 3 – sun gear; 4, 12 – satellite; 5, 10, 13 – shaft; 6, 7 – sprocket; 8 – adjusting housing; 9 – crown wheel; 11, 14 – brush; 15 – part Picture 2 – Kinematic scheme of the appliance for frictional and mechanical coating in metal plaque lubricants The demerit of this appliance is the complexity of the design. In Kirovohrad institute of agricultural machine building there was elaborated the appliance for frictional and chemical coating on the internal working surfaces of parts of the “bushing” type. (Picture 3) [13]. ISSN 2414-3820 , , 2016, . 46 261 1 2 6 7 4 5 3 1 – rotating mechanism; 2 – drive shaft; 3 – disc; 4 – mount; 5 – axis; 6 – part; 7 – polishing unit Picture 3 – Appliance for frictional and chemical coating with application of elastic porous elements The authors highlight the productivity increase but the treatment accuracy remains low. Orel State Agrarian University designed the appliance for antifriction coating of the internal cylinder surfaces of parts of aluminium alloys with oxide coating which was formed by anode- cathode micro-arc oxidation (Picture 4) [14]. The peculiar feature of the appliance is that in the housing, in the springing and in the deforming circular elements there was a through groove for fixing polishing element to prevent its sliding. 1 4 5 623 7 8 9 1 – housing; 2 – circular turning with thread; 3 – retainer washer; 4 – springing element; 5 – deforming element; 6 – polishing element; 7 – through groove; 8 – part; 9 – oxide coating Picture 4 – Appliance for antifriction coating of internal cylinder surfaces of parts of aluminium alloys with oxide coating The advantage of the appliance is the broadening of technological abilities of friction and mechanical laying of antifriction coating through decreasing contact pressure in the area of treatment. The disadvantage is the complexity of the design. In order to increase the wearability of the surfaces under treatment, productivity of the process of coating and the quality of the coating the appliance for friction and mechanical coating of internal cylinder surfaces in the alloy of Ga and In was designed [15]. While treatment of a part the appliance makes simultaneous reciprocating and rotational movement, and the direct ISSN 2414-3820 , , 2016, . 46 262 resistance sintering through the pair “tool-part” allows keeping the material in the condition of melt. The specific feature of the appliance (Picture 5) for FANT of cylinder liners is the presence of two polishing elements and the absence of sputtering of service liquid while treating the inner surface [16]. 1 2 3 4 5 6 7 8 9 1012 1314151617 1 – cover; 2, 15 – pilot bushes; 3 – surface under treatment; 4, 14 – brass rod; 5, 13 – nuts; 6, 12 – moving stock; 7, 16 – barrel; 8 – head; 9 – drawbar; 10 – bolt; 11 – plug coupler; 17 – lever Picture 5 – FANT scheme of cylinder liners The application of the appliance allowed increasing the speed of treatment but the wearability of the parts was not changed. Horlovka branch of Donetsk Polytechnic Institute designed the mounting for FANT of cylinder liners [17], based on the principle of honing. They changed ceramic bars in the honing head for the brass rollers (Picture 6) which have overhang working collars. Picture 6 – Brass roller for the honing head This design enabled increasing the pressure on the working surface of the cylinder and to create conditions for intensive carrying over of the material from the roller onto cylinder. The disadvantage of this design is the failure to adjust the pressure of the tool on the working surface and as a result the quality of treatment decreases. The analysis of the methods of finishing treatment of holes showed that the most effective are the methods of combined treatment from the point of view of increasing wearability and durability of adherence of coatings with basis [18]. The possibility of combining FANT with the methods of the surface-plastic deformation (SPD) will allow increasing the productivity of the process and the quality of finishing treatment of holes. So, on the basis of the vertical honing machine and the honing head we designed the appliance with vibro-oscillating circuit which provides antifriction strengthening treatment of cylinder liners with the formation of constant micro-relief on the inner cylinder surfaces of the parts [19]. The suggested design of the tool let making coating the surface under treatment with antifriction layer as a result of polishing it with polishing bars made of antifriction material ISSN 2414-3820 , , 2016, . 46 263 and feeding to the treatment area of the solution of surface-active agents simultaneously. This enabled harden the surface of the part with the coating (Picture 7). At the same time the treatment productivity remains low. 2218201719 21 1615 10121317834256 14 9 11 1 – housing; 2 – balance spring; 3 – axis; 4 – connecting tubes; 5 – mount; 6, 7 – antifriction bars; 8 – deforming element (roller); 9, 10 – bushing; 11, 13 – bolt; 12 – plunger; 14 – Grower washer; 15 – measuring ring; 16 – rod; 17 – clutch; 18 – connecting tube; 19, 20, 21 – rings; 22 – bushing Picture 7 – Appliance for the combined antifriction and hardening treatment of holes Despite the immense experience of treatment of cylinder liners and the presence of the equipment the author of the FANT method states [20] that the existent appliances of mounting do not provide necessary productivity in mass treatment of cylinders. It is connected with the fact that the polishing elements (tools) are only one-three brass rods with diameter 3…4 mm. which makes to accomplish several passages of the tool in order to cover with brass film all the surface of a cylinder. It important to notice that the designed technologies of FANT of cylinder liners and appliances for their application do not give necessary hardening of working surface of cylinder and do not provide optimum wearability of the part. Taking into consideration the peculiar features of the appliances for FANT of cylinder liners the authors [21,22] developed the appliances which help solving the above-mentioned problems. Conclusion. The analysis of the existent appliances for FANT of cylinder liners enabled making the following conclusions: 1. The employed appliances have low productivity and do not provide high wearability of the part. 2. In order to increase the efficiency of the treatment it is necessary to use the combined schemes, for example, combination of FANT with SPD methods which demands the development of new mounting. 3. The application of the designed by the authors certain appliances for FANT of holes and cylinder liners, in particular, enabled increasing the productivity and the quality of treatment. References 1. . . [ ] / . . , . . , . . // , , . – 2010. – 1(3). – . 104-107. 2. : . . [ ] / .: . . , . . , . . , . . , . . , . . . .: « », 2011. –312 . ISSN 2414-3820 , , 2016, . 46 264 3. [ ] / // ( . . ). – 2010. – 10. – C. 23-28. 4. . . ( ) [ ] / . . // ( . . ). – 2009. – 5. – C. 24-29. 5. . . : . … . . [ ] / . . . – ., 1998. – 108 . 6. . . [ ] / . .- . . . .2, 1998. – . 177-179. 7. .JI. ( ): . … . . [ ] / . . .– .: , 1993.–150 . 8. . ., . ., . . . ( ) . : , 1996. – 107 . 9. . . [ ] / . . , . . // « , , », 2012. – .25(1). – . 3 – 8. 10. . . - [ ] / . . , . . // , 2013. – .26. – . 58 – 62. 11. Mykhailo Chernovol. 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