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1 Available online at ScienceDirect Procedia Engineering 150 (2016 ) International Conference on Industrial Engineering, ICIE 2016 Development and Testing of Profile Shafts Processing Method with Constructive Feed Cutters V.V. Kuts, Yu. A. Malneva, *, V.M. Skantsev b a South-West State University, Str. 50 let Oktyabrya Nr. 94, Kurs, Russia b Bryansk State Technical University, Boulevard 50 let Oktyabrya Nr.7, Bryansk, Russia Abstract Despite their obvious benefits, profile connections currently are not adequately applied in the domestic engineering industry due to the lack of technology and poor elaboration necessary for their production process and tool support. The work contains suggestions on how to improve the performance for the RK-core processing shafts cutters with radial constructive feed and describes the processing method allowing one to exclude the reciprocating harmonic motion. To implement this method, a design procedure was developed for a disc cutter with radial constructive feed which allows performing the calculation of the milling and processing modes design parameters. The software for calculating the structural parameters of milling and processing conditions was as well developed and the results of its test are also presented. The software was used to create a 3D model of a disk cutter, to make prototype mills and conduct field experiments 2016 Published The Authors. by Elsevier Published Ltd. This by Elsevier is an open Ltd. access article under the CC BY-NC-ND license ( Peer-review under responsibility of the. South-West State University, Bryansk State Technical University Peer-review under responsibility of the organizing committee of ICIE 2016 Keywords: Method of processing; RK-profile shaft; modelling; disc cutter; prototype. 1. Introduction Equiaxed profile connection for many years are potentially interesting solution for designers of the various branches of engineering. They have very high load capacity, especially in terms of fatigue loads. The absence of stress concentrators gives advantages to this kind of interfaces over usual spline connections. Existing schemes and treatment methods are based on using the harmonic movements to the work piece and/or the tool. This negatively * Corresponding author. Tel.: address: yuliyamaximencko2010@yandex.ru Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license ( Peer-review under responsibility of the organizing committee of ICIE 2016 doi: /j.proeng
2 V.V. Kuts et al. / Procedia Engineering 150 ( 2016 ) affects the accuracy and performance. Specialized equipment built on these schemes has a complex structure and high cost. In this regard, profiled connections are not adequately applied in the domestic engineering [1]. To improve the performance [1, 2], a constructive feed disc cutter method of processing was proposed. This allowed excluding reciprocating harmonic motion. These movements are carried out by the disc cutter construction. Therefore, special machines and tools are not required (Fig. 1). This method allows to: process short sections and the shaft journal; carry out the pruning of the shaft surface adjacent areas without the use of special tools; increase productivity and accuracy of processing [3-7]. Increased productivity and accuracy of processing is achieved by the following: speed of the shaft and the cutter revolution is equal, movements of the shaft and the cutter have different orientation; axes of the shaft and the cutter are arranged in parallel with respect to each other; the cutter profile has equiaxial contour, its number of apexes and eccentricity is equal to the shaft number of apexes and eccentricity. Equiaxial profile connections exist for many years. They have very high load capacity, especially in terms of fatigue loads. The absence of stress concentrators gives advantages to this kind of interfaces over usual spline connections. Existing schemes and treatment methods are based on using the harmonic movements to the work piece and/or the tool. This negatively affects the accuracy and performance. Specialized equipment built on these schemes has a complex structure and high cost. In this regard, profiled connections are not adequately applied in the domestic engineering [1]. To improve the performance [1, 2], a constructive feed disc cutter method of processing was proposed. This allowed excluding reciprocating harmonic motion. These movements are carried out by the disc cutter construction. Therefore, special machines and tools are not required (Fig. 1). This method allows to: process short sections and the shaft journal; carry out the pruning of the shaft surface adjacent areas without the use of special tools; increase productivity and accuracy of processing [3-7]. Increased productivity and accuracy of processing is achieved by the following: speed of the shaft and the cutter revolution is equal, movements of the shaft and the cutter have different orientation; axes of the shaft and the cutter are arranged in parallel with respect to each other; the cutter profile has equiaxial contour, its number of apexes and eccentricity is equal to the shaft number of apexes and eccentricity. Fig. 1. the scheme of processing equiaxial contour shafts with the radial constructive feed disk cutter.
3 698 V.V. Kuts et al. / Procedia Engineering 150 ( 2016 ) The equation of the cutting edges has the form cosi ( e cos( N i) R f ) N e sin( N i) sini sini ( e cos( N i) R f ) ri ( i, hi ), (1) N e sin( N i) cosi hi 1 where i is a parameter of the i cutting edge initial setup; R f - average radius of the cutter; e - eccentricity; N - number of faces; h i - parameter of the cutting edge h i = 0...B; B - the width of the cutter. To implement this method, a way of the radial constructive feed disk cutter designing has been developed. This way allows performing a calculation of the cutter constructive parameters and processing modes. With the program created for the RK-3 profile shaft size range of 13/08-100/9 mm we made a calculation of the average diameter, number of teeth, the shaft and cutter rotation frequency, plunging providing 10th quality class of accuracy (Table 1). Table 1. Guidelines for the RK-3 profile shaft cutter parameters and processing modes R-3 profile sizes (DPK/2), mm Cutter average radius, mm Number of cutter teeth Shaft and cutter rotation frequency, rpm Plunging, mm/min 13/0, ,98 14/0, ,8 16/ ,9 18/1, ,9 20/1, ,35 22/1, ,13 25/1, ,06 28/1, ,03 32/2, ,03 36/2, ,02 40/2, ,86 45/3, ,77 50/3, ,52 55/ ,35 60/4, ,29 65/4, ,82 72/5, ,8 80/6, ,8 90/ ,75 100/ ,15
4 V.V. Kuts et al. / Procedia Engineering 150 ( 2016 ) For example, table 1 shows that for RK3-20/1.26 mm profile shaft, the average radius of the cutter is 110 mm, the number of teeth is 85, the number of the cutter and the shaft revolutions is 60 rev/min, and the initial value of the plunging is 5.35 mm/min. This ensures the accuracy no lower than quality class 10, the surface roughness after processing no more than Rz 20 microns and the profile distortion no more than 20 microns. With the use of the program [8-10], 3D model of the cutter has been created (Fig. 2). Based on the model, a cutter prototype was manufactured (Fig. 3). Fig. 2. 3D cutter model Fig. 3. the cutter prototype.
5 700 V.V. Kuts et al. / Procedia Engineering 150 ( 2016 ) A sample RK3-20/1.26 mm shaft was made using the cutter (Fig. 4). Fig. 4. a profile shaft sample. Figures 5 and 6 show the changes of the roughness parameter Rz and the profile distortion of the processed shaft. Fig. 5. diagram of the processed shaft roughness parameter.
6 V.V. Kuts et al. / Procedia Engineering 150 ( 2016 ) Fig. 6. diagram of the processed shaft profile distortion changes. The figures show that the value of the parameter Rz is less than 20 microns, and the profile distortion does not exceed 10 microns. 2. Conclusion The results show that the presented method may be suitable for the profile shafts processing. The calculated design parameters of the cutter and processing modes ensure the required processing accuracy. Acknowledgements Research is done under support of RFBR grant No References [1] Y.A. Maksimenko, V.V. Kuts, Machining by a disk mill of variable radius, Russian Engineering Research. 34 (2014) [2] A.G. Ivakhnenko, E.O. Ivakhnenko, A.Y. Altukhov, V.V. Kuts, Revisiting the provision of nanoscale precision of cutting on the basis of dynamic characteristics modeling of processing equipment, Journal of Nano and Electronic Physics. 6 (2014). [3] A.G. Ivakhnenko, V.V. Kuts, M.L. Storublev, A.N. Strukov, Basing of elements in the shaping systems of metal-cutting machines at early stages of design, Russian Engineering Research. 31 (2011) [4] V.V. Kuts, I.V. Kucheryaev, Machine-tool adjustment in machining the housings of composite mills, Russian Engineering Research. 28 (2008) [5] V.V. Kuts, The profile distortion value calculation for shaped to be machined surface at the CAD/CAM - development for assembled shaped mills, Avtomatizatsiya i Sovremennye Tekhnologii. 11 (2004) 5 7. [6] S.G. Emel'yanov, V.V. Kuts, M.S. Merzhoeva, Graphoanalytical design method of combined core drills equipped with replaceable and indexing cutting inserts, Avtomatizatsiya i Sovremennye Tekhnologii. 11 (2003) [7] Y.A. Maksimenko, V.V Kuts, Analysis of changes in error processing rk-profile shaft with teeth resharpening cutters with radial constructive feed, Inzhenernyi zhurnal Spravochnik. (2014) [8] Y.A. Maksimenko, V.V. Kuts, Methods of calculating the geometric parameters of the residual layers of the disc cutter with a variable radius in the processing of RK-profile shafts, Fundamental problems of technology and tehnologii. 299 (2013) [9] Y.A. Maksimenko, V.V. Kuts, Experimental testing of a method of processing and RK-K-profile shaft milling cutters with radial structural supply, Fundamental and applied problems of engineering and technology. 5(2014) [10] Y.A. Maksimenko, V.V. Kuts, Algorithm design disc cutters with radial feed for the constructive processing of RK and K-profile shaft, Vestnik MSTU STANKIN. 27 (2013)
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