Stamping of basic units of machinery bads

Abstract

Havrysh P., Abhari P., Malyhin M., Kassov V.  Stamping of basic units of machinery bads

The conducted analysis and evaluation of the possibilities of manufacturing the basic components of the metal structure of the machine bed showed the need to consider the methods of combined extrusion, as well as the use of stamps with detachable matrices. Obtaining such a complex part as a basic unit by stamping metal processing technology is a promising direction for obtaining a basic unit with high accuracy in accordance with the requirements of the regulatory documentation. In order to clarify the manufacturing technology of the basic unit, mathematical modeling of the processes of precise three-dimensional stamping in closed matrices was performed using the finite element method program DEFORM 2D/3D, which allows you to determine the stress-deformed state and the force mode of the process. As a result of modeling, the dependence of the extrusion force on the displacement of the punch was determined. It was found that the force constantly increases during the forming process and reaches a value of 4.75 MN at the end of extrusion. It is shown that the greatest intensity of deformation is concentrated in the middle of the deformation center of the stamping process. When studying stress in individual parts of machine tools, it is known that due to the unevenness of the load and the concentration of stress in individual nodes, the fatigue strength of the metal structure of the bed and its rigidity become the most important. Therefore, increasing the accuracy of work and the efficiency of welded base units is an urgent goal for scientists. It was determined that precisely the shortcomings and defects of welding can reduce the durability of the machine, the accuracy and quality of the production of parts on the machine. Therefore, improving the metal structure of the machine bed by using the basic assembly increases the accuracy of the machine and its efficiency.

Butt seams in all types of welding - arc, electron beam, plasma, etc. – are the most optimal in relation to stress concentration. The absence of weld defects and in the case of minimizing welding deformations, as well as in the rational design of the seam and smooth connection of the weld to the base metal, residual welding stresses can be minimized. Research has shown that it is possible to reduce residual stresses after welding. The use of stamped base assemblies makes it possible to replace welds with high residual stresses with optimal welds – butt welds.