The Pacific National University, Khabarovsk, Russia

V. М. Davydov, Professor of the Higher School of Industrial Engineering of the Polytechnic Institute, Doctor of Technical Sciences, e-mail: 000005@togudv.ru
S. К. Fedorchenko, Postgraduate Student of the Higher School of Industrial Engineering of the Polytechnic Institute, e-mail: 2016103616@pnu.edu.ru

The processing of shafts from blanks obtained by the forging method is considered. In general, blanks for large-sized shafts differ in the quality of manufacture, however, in some cases, when processing such blanks, difficulties arise such as defects exposure during machining, for example, flakes. Typically this is found when processing the shaft end sections, which have the smallest machining diameters, for press fitting of half-couplings and the oil pump impeller. In such cases, it is necessary to deviate from the technology and the drawing to correct this situation by reducing the diameters, but this does not always eliminate such defects. To solve this problem, a technology has been developed using surface plastic deformation, which avoids significant costs associated with repeating the manufacturing process of a new part. In the course of the research, an algorithm of actions was developed that allows using the deformation method with burnishing tools of different configurations, as well as obtaining a smooth surface without transitions when using different operations for the same surface. A program has been developed for numerically controlled lathes to achieve stable uniform results. This unit has been successfully integrated into the manufacturing process of the turbine shaft. In addition, a finished surface was obtained on the shaft journal, which is closed on both sides by fillets, which does not require refinement by grinding and polishing and makes it possible to harden the surface layer by more than 20% of the initial hardness.

1. Av erchenkov V. I., Vasiliev A. S., Kheifets M. L. Technological heredity in the formation of the quality of manufactured parts. Naukoemkie tekhnologii v mashinostroenii. 2018. Vol. 10. pp. 27–32.
2. Zsolt F. K., Zsolt J. V., Janos K. Improvements of surface tribological properties by magnetic assisted ball burnishing. Surface and Coatings Technology. 2022. Vol. 437. 128317
3. Mitrofanova K. S. Technological quality assurance of the surface layer by surface plastic deformation with a multiradius roller. Technological support and quality improvement of mechanical engineering and aerospace products: Proceedings of the 14th International Scientific and Technical Conference dedicated to the 50th anniversary of the Bryansk Scientific School of Engineering Technologists. Bryansk, 5–7 October 2022. Bryansk : Bryansk State Technical University, 2022. pp. 90–94.
4. Nihal Y., Nedim S., Mert K., Yusuf K. Еnhancing surface integrity of additively manufactured inconel 718 by roller burnishing process. Procedia CIRP. 2022. Vol. 108. pp. 681–686.
5. Vedernikov A. S., Vedernikova I. I. Application of plastic deformation methods in the processing of parts. Reliability and durability of machines and mechanisms : Proceedings of the XIII All-Russian Scientific and Practical Conference. Ivanovo, April 14 2022. Ivanovo : Ivanovo Fire and Rescue Academy of State Fire Service of the Ministry of Emergency Situations of Russia, 2022. pp. 473–477.
6. Mitrofanova K. S. Assessment of the stress-strain state of the hardened surface layer after PSD with a sophisticated tool. Young Russia : Proceedings of the 12th All-Russian Scientific and Practical Conference of Young Scientists with International Participation. Kemerovo, April 21–24, 2020. Kemerovo : Kuzbass State Technical University named after T. F. Gorbachev, 2020. pp. 316031–316034.
7. Kokoreva O. G. Studying the kinetic essence of the process of hardening the surfaces of machine parts by surface plastic deformation. High-tech research as the basis of innovative development of society : Proceedings of the International Scientific and Practical Conference, Samara, June 11 2019. Part 2. Samara : Omega Science LLC, 2019. pp. 96–98.
8. Zabrodin V. A. Restoration of dimensional accuracy of parts by surface plastic deformation with a given redistribution of material: thesis. … of Doctor of Technical Sciences. Komsomolsk-on-Amur, 2001. 284 p.
9. Blumenstein V. Yu., Kukareko V. A. Structural transformations in the surface layer during processing with a multiradius deforming tool. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty). 2018. Vol. 20, No. 2. pp. 75–86.
10. Fedorchenko S. K., Davydov V. M., Ivanishchev Yu. G. Processing of parts by surface plastic deformation by the rolling method. Uchenye zapiski Komsomolskogo-na-Amure gosudarstvennogo tekhnicheskogo universiteta. 2023. Vol. 7. pp. 89–94.
11. Zaides S. A., Mashukov A. N. Application of diamond smoothing technology to improve the microgeometry of high-pressure valve assemblies. Vestnik Kuzbasskogo gosudarstvennogo tekhnicheskogo universiteta. 2019. Vol. 1. pp. 5–14.
12. Yen Y. C., Sartkulvanich P., Altan T. Finite element modeling of roller burnishing process. CIRP Annals. 2005. Vol. 54, Iss. 1. pp. 237–240.
13. Shailesh D., Vijay K. Finite element analysis of roller burnishing process. International Research Journal of Engineering and Technology. 2017. Vol. 04, Iss. 6. pp. 2294–2301.
14. Stalin J., Welsoon W., Prasad B., Avinav A., Vinayagam B. K. An investigation of ball burnishing process on CNC lathe using finite element analysis. Simulation Modelling Practice and Theory. 2016. Vol. 62. pp. 88–101.
15. Cagan S. C., Pruncu C. I., Buldum B. B. An investigation into ball burnishing process of magnesium alloy on CNC lathe using different environments. Journal of Magnesium and Alloys. 2020. Vol. 8, Iss. 4. pp. 1061–1070.
16. Damm P., Adinehvand M., Beutner M., Meichsner G. et al. Analysis of the influence of the initial surface integrity on the result of burnished high torque splined shafts. Materials Research Proceedings. 2024. Vol. 41. pp. 1916–1924.
17. Ahmed R., Sudhanshu K. A critical review of tool design in burnishing process. Tribology International. 2022. Vol. 174. 107717.