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Instrument Making from Composit Materials

#KR-1360


Technology Developing and Creating of Experimental Plant for Instrument Making from Composit Materials to Process Machine-Building Components

Tech Area / Field

  • MAT-COM/Composites/Materials

Status
3 Approved without Funding

Registration date
31.10.2005

Leading Institute
Kyrgyz National Technical University, Kyrgyzstan, Bishkek

Collaborators

  • University of Applied Sciences / Technische Fachhochschule, Germany, Berlin

Project summary

The purpose of the project: Development and creation of skilled installation of manufacturing of tools from composit materials repeatedly raising accuracy of processing of precision details in mechanical engineering. Research, test and an estimation of physical and mechanical properties of the technological tool received in such way. The new technology and the tool will provide repeated reduction of waste products and use of cheaper tools for machining precision details.

The survey. The conducting foreign machine-building and machine-tool constructing firms such as "Ernault Toyoda automation", "MAHO", "Kasto", "Studer" (Germany), "Cincinnati Milacron" (USA), "George Fisher", "Kellenberger" (Switzerland), ‘‘Mark’s machinery ‘‘ and International Ceramic Engineering (Canady) make separate units and elements of machine tools from polymeric materials and polymer-concrete such as "Granitan" and "Rhinocast". Researches connected with manufacturing the tool from composit material were not carried out; therefore in the given project the new "know-how" composit tool is offered.

Traditionally used tools from expensive instrumental and constructional types of steel do not provide the required accuracy of processing because of occurrence of vibrations and fluctuations during cutting, influence of thermal deformations. In these cases the required accuracy is achieved due to the repeated fair processing. The technology offered by us allows to reduce the amount of transitions of processing, time of processing due to high dynamic properties of the tool and to reduce the cost price of manufacturing.

Transition to tools is necessary for maintenance of high efficiency and accuracy from composit materials with high parameters of breaking strength 12 - 20 N/mm2, strength on compression from 100-120 N/mm2, with the module of elasticity 45 - 60 kN/mm2 and having the increased dynamic characteristics.

The urgency of the project is connected with the decision of a problem of creation of a new technological equipment and new materials which allow to operate the elastic deformations of technological system due to use of the progressive tool.

For this purpose we need tools which are strong enough and steady against vibration, capable to work with high modes of cutting - speed and submission. The existing methods of processing demand a lot of transitions of processing that increase the labor input of processing by 25%-35 %. It results in increase in the charge of cutting plates by 15%-18 %, the charge of the electric power by 18%-24%. For example, only within Kyrgyzstan the economic losses from use of the constructional tool equipment have made about 0.4 million dollars. The existing tools from constructional steel are very labor-intensive in manufacturing owing to what they are very expensive and ineffective in maintenance of the required parameters of accuracy. Novelty of scientific and technological decisions makes the theme of the given project actual and corresponding to the world standards.

The project bases on a long-term experience of Kyrgyzstan scientists, which has been accumulated during the process of development of machining facilities and technological tool in KSTU. It also bases on the experience of "arms" scientists in the field of special materials and technologies [ 13, 14, 16, 17 ].

According to the purpose of the project the following primary goals are solved:

  1. Creation of the plant for manufacturing the technological tool from composit material - epogran.
  2. Researches of technological processes of creation of tools on the base of composit materials. Development of techniques of experimental test.
  3. Researches of physic and mechanical properties of Composite Material Tools (CMT), creation of new circuits and modes of processing with the tool from composit materials.

At carrying out of the project the following basic results will be received:
  • The plant is created and the experimental sample party of the technological tool for precision processing is received;
  • Reports, methods of theoretical and experimental researches of processes of creation of tools from composit materials;
  • Theoretical and experimental questions of micromechanics of composites are investigated;
  • Preparation of conditions for serial introduction of the plant.

The results of the project will allow the enterprises to make hi-tech production, to use new opportunities of the tool, to create new workplaces and to provide release of competitive production.The given plant, the technology and the tool are necessary for the enterprises of mechanical engineering of the republic. The consumers of the given tool are "Setyun" works, the Bishkek machine-building factory, "Ala-Tash" enterprise and "Ak-Tilek" joint-stock company. All these enterprises produce machine-building production, have the advanced tool manufactures and are interested in this equipment and the tool.

The results of their application will allow predicting objectively the following technological parameters of efficiency of the given tool:

  • Positive technological effects at final methods of processing;
  • Reduction of labor-intensiveness of machining by 25%-30 %;
  • Increase of accuracy of processing by 20% - 25 %;
  • The steady tendency of improvement of parameters of the tool from Composite Materials(CM)

By results of the project 10 scientific works will be published and 2 patents protecting design and technological features of the plant and the tool will be received.

Scientific value of results consists in creation of the new progressive equipment, technology and the tool, in studying the mechanism of synthesis of composit materials, formation of structure and physic-mechanical properties of the tool from composit materials.

Scientific novelty consists in the establishment of new characteristics of the plant and process regularity of the technological tool from composit materials.


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