Engineering, Energy, Transport AIC

Ihor BABYN – Candidate of Technical Sciences, Associate Professor of the Department of machinery and equipment for agricultural production of Vinnytsia National Agrarian University (St. Soniachna, 3, Vinnytsia, Ukraine, 21008, e-mail: ihorbabyn@gmail.com, https://orcid.org/0000-0002-7070-4957). 

The article presents a comprehensive theoretical and experimental study of the contact area between the tool and the part in the process of ultrasonic smoothing with an initial gap. It is established that the contact area is a determining parameter that affects the distribution of contact pressures, the nature of the deformation of the surface layer, tool wear, and the quality of the machined surface.
At the first stage of implementation, contact pressures reach a maximum with a minimum contact area. There are first and second loading: the first is characterized by the predominance of plastic deformation of micro -unevennesses, the second is characterized by elastic deformation, which leads to the formation of two contact zones - elastic and elastic-plastic.
It has been experimentally proven that the deformation of micro-roughness occurs by pressing the protrusions into the depressions, and not by shear. This was confirmed by the processing of steel samples 45 (hardness 200 HB, initial Ra = 4 μm) using a solid lubricant (cadmium iodide), which eliminates the shear component. After smoothing (gap δ = 4 μm, amplitude ξ = 12 μm, feed S = 0.01 mm/rev, speed V = 90 m/ min, tool VK15, R = 2 mm) the roughness decreased to Ra = 0.25 – 0.32 μm, the tops of micro-roughness became flat, and there were no textures on the micro-sections, which allows us to ignore the non-contact deformation wave.
Experimental determination of the contact shape (deposition of a copper layer on the tool) showed proximity to an ellipse with a difference of semiaxes of no more than 9%. Mathematical models were developed: penetration depth, semiaxes of the ellipse, tool paths in the directions of rotation and feed, areas of elastic-plastic Fpp and full F of the contact zones. The analysis revealed a weak dependence of the area on the processing speed (≤6% in the range of 0 – 2.2 m/s) and independence of Fpp from the feed within certain limits.
The improved model, taking into account the elastic recovery of the impression (radius r₃), determined the optimal feed S = r₁ – r₃ (0.037–0.16 mm depending on h and R), which ensures the stability of contact pressures, the invariance of roughness and maximum productivity. Experimental verification confirmed the consistency of the calculated and empirical data.
The results allow predicting process parameters, optimizing ultrasonic smoothing modes to obtain submicron roughness, strengthening the surface without texture, and improving the performance properties of parts. The developed dependencies are suitable for integration into adaptive processing control systems in digital manufacturing.

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