Engineering, Energy, Transport AIC

Andrii SHTUTS – Doctor of Technical Sciences, Senior Lecturer, Department of Electric Power Engineering, Electrical Engineering and Electromechanics, Vinnitsa National Agrarian University (3, Solnechna str., Vinnitsa, 21008, Ukraine, email: shtuts1989@gmail.com, https://orcid.org/0000-0002-4242-2100).

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).

Pavlo LUTS – Candidate of Technical Sciences, Senior Lecturer of Department of machines and equipment of agricultural production of Vinnytsia National Agrarian University (St. Soniachna, 1, Vinnytsia, Ukraine, 21008, e-mail: luts@vsau.vin.ua). ORCID 0000-0002-3776-8940.

An innovative technological process for manufacturing pipeline flanges using the cold end-rolling method is proposed, which opens new opportunities for improving production efficiency and reducing manufacturing costs. This method significantly reduces metal consumption through the optimal use of the blank, as well as greatly diminishes the labor intensity of the technological process. Consequently, it offers significant economic advantages compared to traditional methods, which often lead to higher material waste and greater resource consumption.
The research has established that the molding process using end-rolling creates a favorable stress-deformed state in most of the deforming areas of the blank, especially in the regions beyond the central zone. This beneficial state promotes uniform load distribution, reduces residual stresses, and improves the strength characteristics of the final product. By creating a more balanced stress profile, the end-rolling process enhances the overall mechanical properties of the flange, leading to greater durability and reliability in the final product.
The cold end-rolling technology is based on sequential plastic deformation of the material by applying radial force to the blank. This ensures not only high geometric accuracy but also improved operational characteristics of the flanges. The uniform distribution of deformations reduces the risk of defects such as cracks, thinning, or warping, significantly extending the service life of the products. Furthermore, the method can achieve consistent results across a wide range of flange sizes and configurations.
Moreover, the developed process is versatile and can be adapted for manufacturing flanges of various sizes, materials, and designs, providing flexibility for different industrial applications. The technique also contributes to reducing material waste and lowering energy consumption, making it more environmentally sustainable than conventional methods. The minimized need for additional processing steps and reduced energy requirements further enhance the cost-effectiveness of this technology.
The implementation of the proposed method in pipeline industry enterprises opens prospects for increasing productivity, reducing production costs, and improving the quality of finished products. This approach represents a significant step forward in the development of modern pressure metalworking technologies, offering a more efficient and environmentally friendly solution for producing high-quality pipeline flanges.

1.    Matvijchuk, V., Shtuts, A., Kolisnyk, M., Kupchuk, I., Derevenko, I. (2022). Investigation of the tubular and cylindrical billets stamping by rolling process with the use of computer simulation. Periodica Polytechnica Mechanical Engineering, 66 (1), 51–58. [in English].
2.    Shtuts, A., Kolisnyk, M., Vydmysh, A., Voznyak, O., Baraban, S., Kulakov, P. (2020). Improvement of Stamping by Rolling Processes of Pipe and Cylindrical Blades on Experimental Research. Actual Challenges in Energy & Mining, 844, 168–181. [in English].
3.    Stuts, A.A. (2020). Computer modeling of the rolling stamping process of cylindrical and tubular blanks using the deform-3d software complex. Vibrations in engineering and technology, 4 (99), 101–113. [in Ukrainian].
4.    Matviychuk, V.A., Kolisnyk, M.A., Shtuts, A.A. (2018). Study of the stress-strain state of the material of the blanks during direct extrusion by the rolling stamping method. Technology, energy, transport of agricultural industry, 3 (102), 77–84. [in Ukrainian].
5.    Matviychuk, V.A., Aliyev, I.S. (2009). Improvement of processes of local rotational pressure processing based on the analysis of deformability of metals. Kramatorsk: DGMA. Monograph. [in Ukrainian].
6.    Kraevsky, V.O., Matviychuk, V.A., Mikhalevich, V.M. (2003). Influence of technological parameters on the kinematics of cold end rolling. Improvement of pressure treatment processes and equipment in mechanical engineering and metallurgy. Kramatorsk-Slovyansk. [in Ukrainian].
7.    Mikhalevich, V.M., Dobranyuk, Yu.V. (2015). Analytical presentation of the maximum radius of cylindrical workpieces during axisymmetric deposition with barrel formation. Herald of mechanical engineering and transport, 1, 59–66. [in Ukrainian].
8.    Matviychuk, V.A., Mykhalevych, V.M., Dobranyuk, Yu.V., Bubnovska, I.A., (2016). Method of determining the plasticity of metals by rolling cylindrical samples into a wedge. IPC G01N 3/08 (2006/01) . No. 109984, September 26, [in Ukrainian].
9.    Kupchuk, I., Kolisnyk, M., Shtuts, A., Paladii, M. (2021). Development of the technological process of forming rings from sheet samples by stamping rollers and rotary hood. Bulletin of the Transilvania University of Braşov. Series I: Engineering Sciences, 14 (63), 2, 1–13. [in English].
10.    Shtuts, A., Kolisnyk, M., Voznyak, O. (2022). Studying the dynamic characteristics of closed system of gravity concrete mixer’s electric drive by means of computer simulation. AGRICULTURAL ENGINEERING, 54, 49–61. [in English].
11.    Shtuts, A.A., Matviychuk, V.A. (2016). Computer modeling of the rolling stamping process of pipe blanks. Technical sciences: Collection of scientific papers. VNAU, 1 (95), 178–184. [in Ukrainian].
12.    Matviychuk, V.A., Kolisnyk, M.A., Shtuts, A.A. (2018). Study of the stress-strain state of the material of the blanks during direct extrusion by the rolling stamping method. Technology, energy, transport of agricultural industry, 3 (102), 77–84. [in Ukrainian].
13.    Matviychuk, V.A. (2007). On increasing the plasticity of metals in cases of the appearance of a neck during stretching. Forging and stamping production Processing of metals by pressure, 9, 18–22. [in Ukrainian].
14.    Mikhalevich, V.M., Lebedev, A.A., Dobranyuk, Y.V. (2011). Modeling of plastic deformation in a cylindrical specimen under edge compression. Strength of Materials, 43 (6), 591–603. [in Ukrainian].
15.    Lebedev, A.A., Mikhalevich, V.M. (2003). On the Choice of Stress Invariants in Solving. Problems of Mechanics. Strength of Materials, 35 (3), 217–224. [in English].