Technology, energy, agriculture transport AIC

Sergii Karnaukh – Ph.D., Associate Professor of the Department "Fundamentals of Machine Design" of the Donbass State Engineering Academy (Akademicheskaya str., 72, Kramatorsk, Ukraine, 84313, е-mail: k_sergii@i.ua, https://orcid.org/0000-0003-2878-4065).

Igramotdin Aliiev – Doctor of Technical Sciences (Eng.), Full Professor, Head of the Metal Forming Department of the Donbass State Engineering Academy ((Akademicheskaya str., 72, Kramatorsk, Ukraine, 84313, е-mail: igramaliev@gmail.com, https://orcid.org/0000-0002-4248-8214).

Viktor Matviychuk – Doctor of Technical Sciences, Full Professor, Head of the Department of Electric Power Stations and Systems of the Vinnytsia National Agrarian University (3 Solnechna St., Vinnitsa, 21008, Ukraine, email: vamatv50@gmail.com , https://orcid.org/0000-0002-7837-5174 ).

Liubov Tahan – Ph.D., Senior Lecturer of the Metal Forming Department of the Donbass State Engineering Academy (Akademicheskaya str., 72, Kramatorsk, Ukraine, 84313, е-mail: l.vik.tagan@gmail.com, https://orcid.org/0000-0002-7628-2142).

A large contribution to the final cost of machine-building products is made by the efficiency of blank production, in which a waste-free shear cut is used. The most promising for the implementation of the method of shear cutting are dies with a differentiated clamping of rolled products. The aim of the work is to develop a new die design with a differentiated clamping of rolled products with high technical and economic characteristics and recommendations for the design of such equipment. On the basis of the developed graph of constructions of dies with a differentiated clamping of rolled products, design features have been identified, which made it possible to create a new die design. Compared with the known structures, in the stamp of the DSEA structure, the transverse dimensions and weight are reduced by an average of 25%, and the height of the open stamped space – by 10%. In the process of dividing in the vertical plane, a constant position of the rolling axis is ensured. The transfer of force to the clamp through the rolling is excluded. The stamp has high rigidity. The stamps of the DSEA design have been introduced at the Odessa PJSC "Stroygidravlika". The economic effect of the implementation was 100000 UAH.

Acceptance test results showed that the dies of the new design are efficient and reliable in operation. The quality of the cut workpieces corresponds to the quality indicators of the workpieces cut on modern similar equipment. On the basis of theoretical analysis, experimental studies and operating experience of dies with differential clamping of rolled products, known and formulated new recommendations for the design of such dies. The main ones are: it is necessary to provide a differentiated clamping of rolled products on both sides of the separation plane, subject to the condition that the clamping force should be one and a half times greater than the cutting force; the die body is preferably box-shaped to compensate for thrust forces and torsional moments of forces; the power parts of the stamp must be made in a closed form with stiffening ribs to ensure strength under cyclic stress conditions.

[1]    Aliieva, L.I., Tahan, L.V. (2020). Resource-saving processes of cold extrusion: a textbook for students. Kramatorsk: DSEA. [in Ukrainian].
[2]    Aliev, I.S. (1988). Radial extrusion processes. Soviet Forging and Metal Stamping Technology. In: English Translation of Kuznechno-Shtampovochnoe Proizvodstvo. Part 3. 54–61. [in English].
[3]    Aliev, I.S., Lobanov, A.I., Borisov, R.S., Savchinskij, I.G. (2004). Investigation of die blocks with split matrixes for the processes of cross extrusion. In: Forging and Stamping Production (Materials Working by Pressure). 8. 21–26. [in English].
[4]    Solovtsov, S. S. (1985). Waste-free cutting of high-quality rolled products in stamps. Moscow: Mechanical Engineering. [in Russian].
[5]    Karnaukh Sergii G., Markov Oleg E., Aliieva Leila I., Kukhar Volodymyr V. (2020). Designing and researching of the equipment for cutting by breaking of rolled stock. The International Journal of Advanced Manufacturing Technology. 109. 9-12. 2457–2464.[in English].
[6]    Karnaukh, S. G. (2010). Improvement of waste-free methods for separating long products and equipment for obtaining high-quality billets: monograph. Kramatorsk : DSEA. [in Russian].
[7]    Lisunets, N.L. (2019). Usage of physical and mathematical simulation for improvement of the processes of metal shear cutting. CIS Iron and Steel Review. 17. 34–38. [in English].
[8]    Lisunets, N.L. (2018). Improving the efficiency of the processes of billets manufacture from rolled metal via shift cutting based on simulation. Chernye Metally. 6. 31–35. [in English].
[9]    Liu, Y., Hua, L., Mao, H., Feng, W. (2014). Finite element simulation of effect of part shape on forming quality in fine-blanking process, Procedia Engineering. 81. 1108–1113. [in English].
[10]    Zheng, Q., Zhuang, X., Zhao, Z. (2019). State-of-the-art and future challenge in fine-blanking technology, Production Engineering 13. 61–70. [in English].
[11]    Hu, X.H., Choi, K.S., Sun, X., Golovashchenko, S.F. (2014). Edge fracture prediction of traditional and advanced trimming processes for AA6111-T4 sheets, Journal of Manufacturing Science and Engineering 136. 021016 (11 pages). [in English].
[12]    Zhao, P.J., Chen, Z.H., Dong, C.F. (2016). Experimental and numerical analysis of micromechanical damage for DP600 steel in fine-blanking process, Journal of Materials Processing Technology 236. 16–25. [in English].
[13]    Wang, S., Chen, Z., Dong, C. (2017). Tearing failure of ultra-thin sheet-metal involving size effect in blanking process: Analysis based on modified GTN model, International Journal of Mechanical Sciences 133. 288–302. [in English].
[14]    Barik, J., Sonkamble, V., Narasimhan, K. (2018). Burr formation and shear strain field evolution studies during sheet metal blanking. IOP Conference Series: Materials Science and Engineering. 418(1):012068 (8 pages). [in English].