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Development and implementation of innovative technologies for manufacturing science-intensive engineering products from layered metal and metal-ceramic materials

Work number - M 35 AWARDED

Author:Borys R., Chornyi A.


Modern trends in the development of the engineering industry are characterized by increased requirements for the quality and performance of products while reducing the cost of their production. To ensure the effectiveness of engineering products in their designs widely used different materials with high relative strength, as well as specific functional properties – aluminum and titanium alloys, steel, ceramics and others.

One of the most pressing scientific and technical problems of the use of different materials in structures is to ensure the quality of the compound parts of dissimilar metals and alloys. For these purposes, layered metal compositions of tubular shape (bimetallic tubular elements (BTE), which are used as adapters for connecting pipelines in fuel and other systems, are widely used. They provide effective connection of pipelines made of different metals.

The sharp competition of mechanical engineering products in the world market requires the mobility of production, and discrete unstable programs of production of products-production of their single copies. The mobility of production can be provided by using the universal equipment of machine-building enterprises, as well as by creating technologies for the manufacture of bimetallic tubular elements from traditional semi-finished products, such as sheet semi-finished metals and alloys, using non-complex die tooling methods of drawing.

In work the actual scientific and practical problem of introduction of innovative technologies of production of products of high-tech mechanical engineering from layered metal and metal-ceramic materials is solved.

Based on the theory of plastic flow and mechanics of composite materials in the interaction of layers of different metals on the boundary surface, as well as extreme energy principles of plastic forming. A mathematical model of the process of joint deformation of two dissimilar metals during drawing with thinning in the heated state is constructed. The interrelation in the form of analytical dependences of the kinematics of the layers flow, the degree of their deformation and the parameters of the stress-strain state on the boundary surface with the initial geometric parameters of the workpiece, the mechanical properties of the layers and the geometry of the working surface of the matrix is established.

On the basis of numerical simulation in CAD / CAE ANSYS and DEFORM-3D systems, confirmation of the main analytical results at the angle of the matrix taper 4°…10°is presented. It is also shown that the maximum compressive stresses and shear strains occur near the surface at the exit from the deformation center on the boundary surface of the workpiece made up of two materials, while the difference in the axial strain rates is zero, which ensures the interaction of the layers. To increase the area of contact stresses and the contact time of layers under load, it is proposed to use an additional angle of 1°…2°on the conical surface of the matrix