A. A. D’yakonov

Capabilities of internal-grinding wheels

On the basis of a modified parameter certificate for internal grinding, a method of identifying the optimal cutting conditions for different components machined by the same wheel is formulated. This method significantly reduces the time for process design in batch production.

Selecting the cutting conditions for plane grinding by the wheel periphery

A method is proposed for the design of a three-stage grinding cycle. The three stages are roughing, finishing, and dwelling. This method increases the productivity by reducing the number of working passes in comparison with the conventional design of plane grinding.

Blank-cutter interaction in high-speed cutting

A method is proposed for determining the resistance to deformation of materials under moderate stress in the shear zone. This method facilitates the study of the strength of materials at high strain rates and temperatures. All the parameters of the mathematical models are calculated; and a test bench for the investigation of the blank-cutter interaction is designed and manufactured, on the basis of the pendulum principle.

Wheel–workpiece interaction in peripheral surface grinding

A model of the wheel–workpiece interaction in peripheral surface grinding is developed. The goal is to predict the microrelief of the blank after repeated microcutting. Models of the abrasive grain, the grinding wheel, individual scratches, and the three-dimensional microrelief of the blank are presented. Experimental results confirm the validity of the model.

Effective Cutting Conditions in Abrasive Machining

Effective cutting conditions are considered in relation to the requirements on the product, for the example of external and plane grinding by the periphery of the wheel. Any technological constraint may be expressed as a region in parameter space. In solving various technological problems, the relevant factors may be analyzed in terms of the satisfaction of particular constraints. The outcome is a region corresponding to a particular constraint in the space of control parameters.

Finishing of laminar systems

A design procedure is proposed for the finishing of surfaces with single-layer and multilayer coatings. The method is based on the calculation of defect-free machining conditions for different types of defects formed in the laminar system, with the subsequent determination of effective cutting conditions in relation to the technological requirements at the surface.

Optimal materials for the manufacture of metal-cutting machines

With the goal of improving machine-tool design, attention focuses on the possibility of manufacturing the components of metal-cutting machines from effective new nonmetallic materials that not only meet all the current requirements on such machines but also in most cases improve their performance. The best results are obtained with metal–concrete structures in which the nonmetallic binder consists of modified cement with chemically active additives. Results from materials science are compared with multiyear production tests of metal-cutting machines based on metal–concrete components, which are characterized by stable performance over time. On that basis, an effective new approach is proposed for the modernization of machine tools at the end of their effective working life, without replacing the fundamental structures. The design of the basic structures is analyzed. The production of metal–concrete components in a specialized department of the manufacturing plant is recommended.

Manufacture of metal–concrete basic components for high-precision lathes

Research and industrial experience with machine tools show that strict requirements on lathe performance may be met by using frames and bases made of nonmetallic polycrystalline materials (metal–concrete composites). A metal–concrete composite is a casting of the required structure consisting of a massive nonmetallic component, a reinforcing housing, and a set of metallic inserts.

Thermal behavior in the grinding of laminar systems

The proposed model of the temperature field in a laminar system takes account of the system’s structure and the thermophysical properties of the material in each layer, as well as technological factors such as the position and intensity of the heat source and the heat transfer to the grinding fluid. Accordingly, the model may be used in identifying the limiting permissible grinding conditions in terms of heating of the layers in the system.

Automated Monitoring System for Self-Synchronizing Vibrational Drives

An automated monitoring system has been designed to maintain stable operation of self-synchronizing vibrational drives. By means of the system, information is collected and automatically processed. A built-in electrical feedback loop ensures synchronous drive operation.