Факультет технічних систем і енергоефективних технологій (ТеСЕТ)
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Item Optimization of Surface Roughness Based on turning parameters and insert geometry(DAAAM Int., 2022) Vukelic, D.; Prica, M.; Іванов, Віталій Олександрович; Иванов, Виталий Александрович; Ivanov, Vitalii Oleksandrovych; Jovicic, G.; Budak, I.; Luzanin, O.This study is focused on dry longitudinal turning of AISI steel using CVD coated cutting inserts. The mashining was conducted at different levels of cutting speed, feed, depth of cut, corner radius, rake, inclination and approach angels.Item Development of Flexible Fixtures with Incomplete Locating: Connecting Rods Machining Case Study(MDPI, 2022) Іванов, Віталій Олександрович; Иванов, Виталий Александрович; Ivanov, Vitalii Oleksandrovych; Botko, F.; Dehtiarov, I.; Kočiško, M.; Evtuhov, A.; Павленко, Іван Володимирович; Павленко, Иван Владимирович; Pavlenko, Ivan Volodymyrovych; Trojanowska, J.The rapid development of manufacturing in recent years has led to a significant expansion of the technological capabilities of modern metal-cutting equipment. Therefore, the modern approach to intensifying production requires an advanced fixture design. Design and manufacture of flexible fixtures capable of machining similar shapes and sizes of complex geometry parts reduce setup time. The article aims to design flexible fixtures for parts such as one-piece connecting rods under incomplete locating conditions. The advantages are the minimum number of parts and tool availability for multi-axis machining connecting rods in one setup. This approach, combined with up-to-date machining centers and industrial robots, can increase the production efficiency of manufacturing non-removable connecting rods. This effectiveness is in a decrease in the number of operations by 5–7 times, fixtures—by 3–4 times, and machine tools—by 3–5 times, depending on the type of a non-removable connecting rod and its design features. The numerical simulation results of the proposed fixture design confirmed the comprehensive technological capabilities and dynamic characteristics. Particularly, a decrease in displacements and oscillation amplitudes up to 7% compared to the full-basing locating chart was provided. It is determined that the system “fixture–workpiece” entirely meets all the strength, accuracy, and rigidity parameters, which allows you to perform machining with intensive cutting modes. The amplitudes of oscillations do not exceed the tolerances on the dimensions of these surfaces, established by requirements for non-removable connecting rods, and all displacements are elastic. During numerical simulation, the workpiece position remained stable at all machining steps.Item Classification of Separation Equipment by Design and Technological Features(European Alliance for Innovation, 2022) Іванов, Віталій Олександрович; Иванов, Виталий Александрович; Ivanov, Vitalii Oleksandrovych; Павленко, Іван Володимирович; Павленко, Иван Владимирович; Pavlenko, Ivan Volodymyrovych; Caganova, D.; Ляпощенко, Олександр Олександрович; Ляпощенко, Александр Александрович; Liaposhchenko, Oleksandr Oleksandrovych; Дем`яненко, Марина Миколаївна; Демьяненко, Марина Николаевна; Demianenko, Maryna Mykolaivna; Лобов, Євгеній Сергійович; Лобов, Евгений Сергеевич; Lobov, Yevhenii Serhiiovych; Golokhvost, O.Production range increasing causes many obstacles to ensure the work of the chemical industry. Production must respond quickly to the slightest change and must be customer-oriented. Due to this, there is a general trend towards increasing production flexibility by introducing modular systems. Thus, there is a need to classify existing solutions to develop flexible systems based on them. The article contains the analysis of chemical industry development tendencies, a methodology of research of modular separation devices, and their classification by design and technological features. The study result is a design and technological classification with a code that can optimize various separation devices. As a result of experimental research, preliminary and acceptance tests of experimental samples, the main hydrodynamic and separation characteristics of modular separation devices and combined multifunctional separators are determined: hydraulic resistance 0.15–2.00 kPa for units and 15–30 kPa for devices; effective capture of particles from the size of 5 μm; efficiency of separate stages of modular separation devices is about 70–90 %; efficiency of combined multifunctional separators is approximately 99.5–99.9 %. The offered multipurpose separators equipped with dynamically regulated modular separation devices do not concede to world analogs by the main technical characteristics of combined multistage separators worldwide.Item Using Regression Analysis for Automated Material Selection in Smart Manufacturing(MDPI, 2022) Павленко, Іван Володимирович; Павленко, Иван Владимирович; Pavlenko, Ivan Volodymyrovych; Pitel, J.; Іванов, Віталій Олександрович; Иванов, Виталий Александрович; Ivanov, Vitalii Oleksandrovych; Берладір, Христина Володимирівна; Берладир, Кристина Владимировна; Berladir, Khrystyna Volodymyrivna; Mizakova, J.; Колос, Віталій Олександрович; Колос, Виталий Александрович; Kolos, Vitalii Oleksandrovych; Trojanowska, J.In intelligent manufacturing, the phase content and physical and mechanical properties of construction materials can vary due to different suppliers of blanks manufacturers. Therefore, evaluating the composition and properties for implementing a decision-making approach in material selection using up-to-date software is a topical problem in smart manufacturing. Therefore, the article aims to develop a comprehensive automated material selection approach. The proposed method is based on the comprehensive use of normalization and probability approaches and the linear regression procedure formulated in a matrix form. As a result of the study, analytical dependencies for automated material selection were developed. Based on the hypotheses about the impact of the phase composition on physical and mechanical properties, the proposed approach was proven qualitatively and quantitively for carbon steels from AISI 1010 to AISI 1060. The achieved results allowed evaluating the phase composition and physical properties for an arbitrary material from a particular group by its mechanical properties. Overall, an automated material selection approach based on decision-making criteria is helpful for mechanical engineering, smart manufacturing, and industrial engineering purposes.Item Flow Modeling in a Vortex Chamber of a Liquid–Steam Jet Apparatus(MDPI, 2022) Мерзляков, Юрій Сергійович; Мерзляков, Юрий Сергеевич; Merzliakov, Yurii Serhiiovych; Павленко, Іван Володимирович; Павленко, Иван Владимирович; Pavlenko, Ivan Volodymyrovych; Ochowiak, M.; Іванов, Віталій Олександрович; Иванов, Виталий Александрович; Ivanov, Vitalii Oleksandrovych; Agarwal, P.The article investigated the flow of boiling streams through a nozzle with an oblique cut. Due to this flow organization, deviation from the nozzle axis at the vortex chamber inlet occurred. The study of flow modeling in the inlet section was carried out. The flow design and the calculation scheme of the vortex liquid–steam jet apparatus were proposed. Analytical expressions between the main operating parameters were obtained according to the developed mathematical model. A recommended oblique-cut angle for the active-flow nozzle was evaluated considering the transition through the first critical section based on the tangential velocity flow model. Validation of the mathematical model in the inlet section of the vortex chamber was provided based on the comparison with available experimental data. Flow visualization in the inlet section of the vortex chamber was obtained. The assumption of uneven flow distribution was confirmed experimentally. Overall, the boiling liquid flow was implemented in the active flow nozzle. The obtained scientific and practical results help to determine geometric parameters and physical characteristics of the vortex-type liquid–steam jet apparatus at the design stage. The obtained results were implemented to modernize vacuum units based on vortex type liquid–steam jet apparatuses.Item Locating Chart Choice Based on the Decision-Making Approach(MDPI, 2022) Іванов, Віталій Олександрович; Иванов, Виталий Александрович; Ivanov, Vitalii Oleksandrovych; Botko, F.; Kolos, V.; Павленко, Іван Володимирович; Павленко, Иван Владимирович; Pavlenko, Ivan Volodymyrovych; Hatala, M.; Antosz, K.; Trojanowska, J.Modern manufacturing engineering requires quick and reasonable solutions during the production planning stage, ensuring production efficiency and cost reduction. This research aims to create a scientific approach to the rational choice of a locating chart for complexly shaped parts. It is an important stage during the manufacturing technology and fixture design process. The systematization of the designed and technological features of complexly shaped parts and the definition of the features that impact a locating chart create the fundamentals for justification. A scientific approach has been developed using the complex combination of the part’s features and a decision-making approach using the example of bracket-type parts. The matrix of design and technological features of parts was developed including steel AISI 3135 and cast iron DIN 1691. The classification of locating charts for bracket-type parts was defined. A mathematical model of the rational choice of the locating chart according to the structural code of the workpiece was verified in case studies from the practice. As a result, a decision-making approach was applied to the rational choice of the locating chart for any bracket-type part. The proposed solutions improve the production planning stage for machine building, automotive, and other industries.Item Composition, Structure, and Properties of Ti, Al, Cr, N, C Multilayer Coatings on AISI W1-7 Alloyed Tool Steel(MDPI, 2022) Loskutova, T.; Hatala, M.; Pogrebova, I.; Nikitina, N.; Bobina, M.; Radchenko, S.; Харченко, Надія Анатоліївна; Харченко, Надежда Анатольевна; Kharchenko, Nadiia Anatoliivna; Kotlyar, S.; Павленко, Іван Володимирович; Павленко, Иван Владимирович; Pavlenko, Ivan Volodymyrovych; Іванов, Віталій Олександрович; Иванов, Виталий Александрович; Ivanov, Vitalii OleksandrovychNew methods of diffusion metallization of AISI W1-7 steel have been developed. The paper proposes a comparative analysis of the properties and characteristics of AISI W1-7 steel after three methods of chemical heat treatment: diffusion nitriding, nitrogen titration by physical deposition from the gas phase, and diffusion chromium plating with subsequent titanium alloys. The results are presented as a comprehensive analysis of coatings: metallographic, micro-X-ray spectral, X-ray phase, durometric, heat resistance, and wear resistance. It is established that multilayer protective coatings are formed as a result of treatments. It is shown that the coatings consist of carbide and nitride zones, intermetallic, and an Al2O3 layer outside the coating. The coatings have been found to contain barrier layers that prevent aluminum from penetrating the substrate. The maximum microhardness is typical for layers based on titanium carbide—30.3–35.5 GPa and titanium nitride—22.0–22.6 GPa, heat-resistant steels AISI W1-7 at a temperature of 900 °C in 4.2–8.5 times and wear resistance under sliding friction without lubrication up to 5.4 times compared to samples without treatment.Item Impact of Nitrocarburizing on Hardening of Reciprocating Compressor’s Valves(MDPI, 2022) Берладір, Христина Володимирівна; Берладир, Кристина Владимировна; Berladir, Khrystyna Volodymyrivna; Hatala, M.; Говорун, Тетяна Павлівна; Говорун, Татьяна Павловна; Hovorun, Tetiana Pavlivna; Павленко, Іван Володимирович; Павленко, Иван Владимирович; Pavlenko, Ivan Volodymyrovych; Іванов, Віталій Олександрович; Иванов, Виталий Александрович; Ivanov, Vitalii Oleksandrovych; Botko, F.; Гусак, Олександр Григорович; Гусак, Александр Григорьевич; Husak, Oleksandr HryhorovychOne of the urgent problems in reciprocating machinery is ensuring the functional properties of direct-flow valves. Coatings of these parts should increase energy efficiency, reduce compressed gas temperature, and increase compressor performance. In this article, the effect of nitrocarburizing in pastes on increasing the performance and resource of such valves was studied. The primary research methods were metallographic and electron-metallographic research of the surface layer structure of steel 60Si2Cr. Comparison with similar characteristics obtained for stainless steel 09Cr15Ni8Al was also performed. As a result, it was determined that nitrocarburizing of carbon spring steel 60Si2Cr leads to a greater depth of the diffusion layer than nitrocarburizing of alloyed chromium-nickel steel 09Cr15Ni8Al. Simultaneously, the diffusion layers of both types of steel are almost the same. Simultaneously, the increase in the endurance limit of 60Si2Cr steel during nitrocarburizing is about 1.3 times compared to untreated material. Finally, the predictive maintenance showed that the evaluated lifetime of nitrocarburized valves increases by 5.7 times compared with untreated valves.Item Method for an Effective Selection of Tools and Cutting Conditions during Precise Turning of Non-Alloy Quality Steel C45(MDPI, 2022) Івченко, Олександр Володимирович; Ивченко, Александр Владимирович; Ivchenko, Oleksandr Volodymyrovych; Іванов, Віталій Олександрович; Иванов, Виталий Александрович; Ivanov, Vitalii Oleksandrovych; Trojanowska, J.; Жигилій, Дмитро Олексійович; Жигилий, Дмитрий Алексеевич; Zhyhylii, Dmytro Oleksiiovych; Ciszak, O.; Залога, Ольга Олександрівна; Залога, Ольга Александровна; Zaloha, Olha Oleksandrivna; Павленко, Іван Володимирович; Павленко, Иван Владимирович; Pavlenko, Ivan Volodymyrovych; Гладишев, Дмитро Павлович; Гладышев, Дмитрий Павлович; Hladyshev, Dmytro PavlovychThe paper presents a constructing methodology for a modern approach to tools selection and solving the problem of assigning optimal cutting parameters for specific production conditions. The mathematical formulation determining the extreme values of the technological process optimality criteria is obtained. A system of technical and economic quality indicators for cutting tools is proposed. This system allows principles’ implementation of decentralization and interoperability “Industry 4.0” via finite element modeling of the cutting process based on solving the problem of orthogonal free cutting modeling. The proposed methodology further usage is possible by creating a standardized database on the parameters of the tool: the adhesive component of the friction cutting coefficient for processing of a specific pair of cutting and tool materials (or tool coating material) and the impacts of the cutting-edge radius on cutting efficiency of a particular material.Item The Effect of Blade Angle Deviation on Mixed Inflow Turbine Performances(MDPI, 2022) Chelabi, M.A.; Saga, M.; Kuric, I.; Basova, Y.; Dobrotvorskiy, S.; Іванов, Віталій Олександрович; Иванов, Виталий Александрович; Ivanov, Vitalii Oleksandrovych; Павленко, Іван Володимирович; Павленко, Иван Владимирович; Pavlenko, Ivan VolodymyrovychThe choice of blades for mixed turbines is to achieve the required deflection with minimal losses. In addition, it is necessary that the blade functions without a detachment in a wide area outside the nominal operating point of the machine. In the blade profile study, it is required to satisfy the conditions relating to fluid mechanics and those relating to the possibility of realization of construction. The work carried out presents the effect of the blade deviation angle on the geometric blade shape and the performance of the mixed inflow turbine on keeping the same rotor casing in order to improve its performances. It was remarked that the efficiency is proportional to the deviation angle’s increase, but the rotor became heavy. It has been determined that the effect of the blade deviation angle on mixed inflow performances decreases dramatically starting from the angle −20° for a 100% of machine load. It was urged to avoid relying on angles greater than −20 as values for blade deviation angles. The study noted that the maximum obtained in the output work and power is related to the highest the efficiency for a specific optimum design case (−35° of deviation blade angle) due to the increase in the contact surface between the blade and the fluid, but the problem is that the rotor gets a little heavy (4.37% weight gain). Among recommendations, attention was given to the more significant absolute exit kinetic energies, for values of deviation blade angle between -10° and −20°, where an exhaust diffuser is recommended to use to recover a part of it into a greater expansion ratio. These simulation results were obtained using a CFD calculation code-named CFX.15. This code allowed for the resolution of the averaged dynamic equations governing the stationary, compressible, and viscous internal flow.