For many decades, non-ferrous metals are very popular for the manufacture of various products. Technologies and modern methods of production allow you to speed up the process itself, as well as improve the quality of the final product.

Possess a characteristic shade and high plasticity. Their prey is carried out from the earthly rock, where they are in a very small amount. Processing of non-ferrous metals costs forces and finance production, but it brings a huge profit. Products from them have unique characteristics inaccessible in their manufacture of black materials.

All non-ferrous metals are divided into several groups in their properties:

  • severe (tin, zinc, lead);
  • lungs (titanium, lithium, sodium, magnesium);
  • small (antimony, arsenic, mercury, cadmium);
  • scattered (Germany, Selenium, Telllur);
  • precious (platinum, gold, silver);
  • radioactive (plutonium, radium, uranium);
  • refractory (vanadium, tungsten, chrome, manganese).

The choice of groups used in the production of non-ferrous metals depends on the desired properties of the final product.

Basic properties

- Plastic metal with good thermal conductivity, but low resistance to electricity. It has a golden color with a pink sweat. It is rarely used independently, more often added to alloys. Apply metal for the manufacture of instruments, machines, electrical equipment.

- The most popular alloy with copper is made by adding tin and chemicals. The resulting raw material has durability, flexibility, plasticity, it is easy to cow and it is difficult to wear out.

- Conducts electricity well, refers to plastic metals. It has a silver shade and low weight. Self-resistant to corrosion. Used in military business, food industry and related industries.

- Pretty fragile colored metal, but resistant to corrosion and plastic, if he is heated to a temperature of 100-150 ºC. When it is assisted, corrosion-resistant coating on products, as well as various steel alloys.

When choosing a non-ferrous metal for the future part, it is necessary to take into account its properties, know all the advantages and disadvantages, as well as consider the options for alloys. This will create the highest quality product with specified characteristics.

Using a protective coating

To preserve the initial look and functionality of the product, as well as protect it from atmospheric corrosion, special coatings are applied. The processing of the product with paint or primer is the easiest and most effective method of protection.

To achieve a larger effect on the purified metal, the primer is applied in 1-2 layers. It protects against destruction and helps paint better stay on the product. The choice of funds depends on the type of non-ferrous metal.

Aluminum treatment is produced by zinc-based primers or urethane paints. Brass, copper and bronze do not require additional processing. When damage occurs, polishing and applying epoxy or polyurethane varnish is carried out.

Methods for applying a protective layer

The choice of coating methodology depends on the type of non-ferrous metal, financing the enterprise and the desired product characteristics.

The most popular method of processing non-ferrous metals to protect against damage is the electroplating. A protective layer of special composition is applied to the surface of the product. Its thickness is adjustable depending on the temperature mode at which the part will be operated. The more sharp climate, the greater the layer.

The electroplated method of processing parts in the construction of houses and machines is especially popular. There are several variations of the coating.

- It is carried out using chromium and alloys based on it. The part becomes shiny, the metal after processing is resistant to the action of high temperatures, corrosion and wear. Especially popular method in industrial production.

- It is carried out using current, the action of which causes the formation of a film in the processing of aluminum, magnesium and the alloys-like alloys. The final product is resistant to the action of electricity, corrosion and water.

- It is carried out using a mixture of nickel and phosphorus (up to 12%). After coating, the parts are subjected to heat treatment, which increases the resistance to corrosion and wear.

The method of galvanic processing of parts is quite expensive, therefore its use is difficult for small industries.

Additional methods

Metalization by spraying refers to budget options. A molten mixture is applied to the surface of the product with a air jet.

There is also a hot method of applying a protective layer. Details are immersed in the bath, inside which is molten metal.

With a diffusion method, the protective layer is created under conditions of elevated temperature. Thus, the composition penetrates into the product, which increases its resistance to external influences.

Application on a non-ferrous metal from which the part is made, another, more persistent, is called clamping. The process implies casting, rolling, press and further forging of the product.

Modern technology processing

There are several basic methods for processing non-ferrous metals. They are divided into several groups depending on the technology and temperature regime: hot and cold, mechanical and thermal.

The most popular of them:

  • welding (, chemical, gas, arc, electric, contact);

Transcript.

1 Ministry of Education and Science of the Russian Federation State Educational Institution of Higher Professional Education "Tyumen State Oil and Gas University" November Institute of Oil and Gas (Branch) Working Program Discipline Technology Processing Materials for the specialty Installation and technical operation of industrial equipment (by industry) Noyabrsk, 2010 G.

2 2 Approved by the subject (cyclo) Commission of Oilfield Disciplines Protocol 9 from May 13, 2010. Chairman A.Yu.Tugolukova Chairman of PCC IDDD and SD S.N. Farrenyuk compiled in accordance with government requirements for a minimum of the content and level of graduate preparation in the specialty and on the basis of an exemplary learning discipline program "Material processing technology", IPR SPO Ministry of Education of Russia, "Approve" Deputy Director UMR E.V. Bakiyev "May 14" 2010 Developed: Novichkova G.V. - Lecturer of general professional disciplines Reviewers: Piskareva I.A. - teacher of general professional and special disciplines Demyanov A.A. General Director of Yamalspets Center

3 3 Explanatory note The work program of the educational discipline "Material processing technology" is intended for the implementation of state requirements for the minimum content and level of graduates of graduates in the specialty "Installation and technical operation of industrial equipment" (by industry), and is one for all forms of training in the SPO system . Educational discipline "Material processing technology" is general professional. As a result of studying the educational discipline, the student must: have an idea: the relationship of the discipline "Technology processing technology" with other general professional and special disciplines; on the applied nature of the discipline within the framework of the specialty; On the prospects for development and the role of general professional knowledge in professional activities; on current trends in the development of materials processing; about the foundry; on pressure processing; about welding production; on the procurement processing of blanks; on physical processes and phenomena accompanying chip formation; about electrochemical methods of processing parts; appointment, classification, principle of operation and scope of metal cutting machines; the design of the main metal cutting tools; safety rules when working on metal cutting machines; Equipment of fixtures of metalworking machines; The main provisions of technological documentation; methodology for calculating cutting modes; Main technological methods of formation of blanks; device and principle of action of metalworking machines; To be able to: choose a rational way to handle parts; make a technological and other documentation in accordance with the current regulatory framework; make calculations; Fill out a technological map of mechanical processing of the workpiece;

4 Select the design and geometric parameters of the cutter for the specified processing conditions; select the tools and control the geometric parameters of the instrument; determine the optimal cutting speed for the specified processing conditions; determine the type of machine according to its model; determine the main and auxiliary movements in the machine; read the kinematic scheme of the machine; define typical machine mechanisms; Make a list of processing operations, choose a cutting tool and equipment for shaft processing, holes, grooves, threads and gear. Formed in students in the process of studying the discipline of submission, knowledge, skills on sections (topics) are given in the section "Content of the educational discipline" of this program. The teaching of the academic discipline should have a practical orientation and are carried out in close relationship with general professional and special disciplines. The use of interdisciplinary bonds ensures continuity in the study of the material and eliminates duplication, which allows you to rationally distribute time. In the process of studying the academic discipline, students are constantly drawn to the attention of safety, labor protection, industrial sanitation, fire safety, environmental safety and environmental protection. When expiring the material, the unity of terminology, designations, units of measurement in accordance with the current standards are observed. For better assimilation by students of educational material, classes are provided to carry out under the application of modern technical training. In total, 104 hours were allocated to study this discipline, from the bottom 80 hours of audit classes, which include: 50 hours of lecture and combined classes; To secure the theoretical material and the acquisition of skills in the choice of element base, it is planned to perform laboratory and practical classes in an amount - 30 hours and 24 hours is assigned to independent extracurricular operation. Forms and types of control: -teral control is one of the main types of knowledge checks, skills and skills of students. When organizing current control, it is necessary to achieve conscious assimilation by students of educational material, not allowing large intervals in the control of each student, in this case the students stop regularly prepare for classes, and 4

5 Therefore, and systematically fix the material passed. Rubber control allows you to determine the quality of studies by students of educational material on sections, subjects of the subject. Such control is carried out several times in the semester: in the form of 1-binding test work, control and credit and inspection lessons, tests for laboratory work and practical training. The final control of the discipline "Material processing technology" is carried out in accordance with the working curriculum at the end of the study of the course (4th semester) in the form of differentiated testing. five

6 6 Thematic plan of academic discipline names of sections and those Maxim. Student's training load Number of classroom clocks Total including LPZ Introduction 2 2 Section 1 Technological methods of production of workpieces 1.1 Technological processes in mechanical engineering 1.2 Foundry production bases 1.3 Pressure processing technology 1.4 Production technology Welding blanks 1.5 Production technology of all-in-page connections Section 2 Methods of mechanical processing of parts Machines 2.1 Preliminary processing of blanks Samost. Student work Metal processing cutting Section 3 Metal processing cuts. Metal-cutting tools and machines Machine-cutting machines Turning machines, used machines and tools 3.3 Planing and dulling, applied tool and machines

7 7 3.4 Drilling, coinening and deployment, applied tool and machines 3.5 Milling, applied tool and machines 3.6 Dental cutting, threads, applied tools and machines 3.7 Stretching, applied tool and machines 3.8 Grinding, applied tool and machines 3.9 Fundamentals of automation of metal cutting machines 3.10 Methods Electrochemical processing of metals, methods of radiation processing Section 4 Production of parts on machine machines 4.1 Processing of outer surfaces of rotation 4.2 Processing of internal surfaces of rotation 4.3 Processing of planes, grooves, shaped surfaces 4.4 Processing of threaded and gear surfaces Examination 2 2 Starting only on discipline: List of practical training : 1. Technological process structure 2. Rules for processing technological documents. 3. Soldering technology. 4. Blood technology.

8 5. Determining the time spent on the cut, editing blanks, cutting rods, centered. 6. Measurement of geometric parameters of drills, centers and sweeps. 7. Study of the milling process. 8. Studying tools for cutting gear beams. 9. Studying the tool for threading. 10. Studying grinding process. 11. Electrochemical processing of metals. 12. Typical technological process of processing stepped and smooth shaft. 13. Typical technological process of manufacture of sleeves. 14. Typical technological process of manufacturing cabinet parts. 15. Typical technological process of making gear wheels. eight

9 9 CONTENTS OF EDUCATIONAL DISCIPLINE INTRODUCTION OF THE COMMUNICATION OF DISCIPLINES "MATERIAL TRAINING TECHNOLOGY" with other disciplines; the history of the emergence and development of science on the cutting of metals; Tasks of the discipline "Material processing technology"; Achievements of innovators production. The content of the discipline "Material processing technology", its connection with other academic disciplines. Prospects for the development of mechanical engineering, machine-tooling and the instrumental industry. Commonwealth of science and production, achieving innovatives of production. Section 1 Technological methods of production of blanks Theme 1.1 Technological processes in mechanical engineering Definition of the production and technological process and its structure; Types of technological documents and rules for their design. Production and technological process. Structure of the technological process. Types of technological processes. Types of technological documentation. Rules for issuing technological documents. Practical work 1 Structure of the technological process Practical work 2 Rules for issuing technological documents. Independent work of students to prepare a presentation, find videos

10 10 Topic 1.2 Founding Basics Production Molding Technology Molding method in Opets; technology and alignment methods in a special way; The advantages of each type of special casting and its scope. Classification of methods of making castings. Making castings in sandy forms. The concept of the manufacture of castings with special methods of casting in shell forms, according to the models, in metal forms (cokil), centrifugal casting, injection molding. Topic 1.3. Pressure processing technology The essence of processes occurring during cold and hot pressure processing; varieties of pressure processing; Temperature mode of cold and hot pressure pressure; Forging operations and tools used for forging; The process of rolling, drawing, forging, pressing, stamping. Cold and hot deformation. Plasticization of metals and resistance to deformation. Purpose of heating before pressing pressure. The concept of pressure interval pressure. Classification of pressure processing. Rolling. The concept of the technological process of rolling. Production of rolling production. Stuffing, source blanks and finished products. The essence of forging. Basic operations, tool. The concept of the technological process of forging. Hot volume stamping, concept of the technological process of hot volume stamping. Topic 1.4. Technology of production of workpieces welding use of welding in mechanical engineering; Features of melting and pressure welding;

11 11 Different types of welding; types of welded joints depending on the parts are welded; Welding methods depending on the materials weldable. Basics of welding production. The use of welding in mechanical engineering. Welding of melting: manual arc welding, semi-automatic arc welding under flux, electroslak welding, in the environment of protective gases. Pressure welding: contact electric welding, butt contact welding, point, suture, condenser welding. Friction welding, cold welding. Topic 1.5. Technology of production of in-block connections Soldering and gluing technology; Basic technological methods of formation of blanks; To be able to: choose a rational way to get a workpiece; determine the quality parameters of the obtained surfaces; characterize the method of obtaining the workpiece; Perform soldering and gluing products. Soldering and gluing details. Applying soldering and gluing in mechanical engineering. Types of solders, fluxes. Glue varieties. Soldering and gluing technology. Practical work 3 Soldering technology. Practical work 4 gluing technology. Independent work of students to prepare a presentation, find videos topic 2.1. Preliminary processing of blanks of varieties of pretreatment of blanks; technology of cutting, editing, ridges of rods, cutting rods, centers; be able to:

12 Determine the time spent on the execution of procurement operations. Riding, editing blanks, ripping rods, cutting rods, centers. Practical work 5 Determination of time spent on the cut, editing of blanks, cutting rods, centers. Independent work of students to prepare a presentation, find videos topic 2.2. Processing of metals cutting physical phenomena accompanying the process of cutting metals, their effect on the quality of processing of the workpiece; The influence of various factors for cutting speed; Forces arising from cutting metals. The physical foundations of the cutting process. Deformation of the metal in the process of cutting, the formation of chips, chip types. The phenomenon of rigging, the causes of the outflow on the cutting. Riding and shrinkage chips. Cutting force, heat dissipation when cutting. Work performed when cutting. Sources of heat formation. Power spent during cutting. Power and factors affecting the cutting speed. Determination of optimal speed with formulas and tables. Norming machinery. Determining the time spent on the processing of the part. Section 3 types of metal processing cutting. Metal cutting tools and machine tools Topic 3.1. Metal cutting machines Classification of metal cutting machines; The value of letters and numbers in the machine brands; transmission in machines; Passport details. 12

13 13 Classification of machines according to the degree of versatility. Groups and types of machine tools according to ENioms system. The value of letters and numbers in the brands of machines. Movement in the machines: the main, auxiliary. Transmission in machines. Kinematic schemes of machines, kinematic chains. Setting the kinematic chain. Passport details. Independent work of students to prepare a presentation, find videos Topic 3.2. Turning machines used machines and tools Types and constructions of cutters depending on the processing; Corners of the cutter; surface of the workpiece; main cutting indicators; varieties of lathes, their scope; be able to: define a group, type, parameters of a metal cutting machine on a brand; determine the power of the machine, adjust the cutting indicators on the passport data of the machine; determine the main movements and auxiliary movements in the machine; Select the design and geometric parameters of the cutter for the specified processing conditions; assign optimal cutting modes during turning; Work with kinematics of lathes. Turning process. Types and design of cutters for turning. The main elements of the cutter. Surface treated cutter blanks. Source planes to determine the corners. Corners of the cutter. The constructions of the cutters depending on their purpose and types of processing. Expansion of the range of cutters due to equipping with separate plates. Methods for fastening the plates to the cutter holders. Main cutting indicators: cutting depth, feed, cutting speed. Causes wear, cutter durability, cutter wear criteria. Turning machines: screw, revolving, windy and carousel, lathe machines and semi-automatic, the principle of their work. General information about machines, appointment and scope of their use, consideration of the kinematics of these machines.

14 14 Topic 3.3. Planing and dragging, applied tool and machine tools features planing and dulling process; classification and purpose of planing and slot machines; The varieties of planing and slotting machines, their kinematics, main nodes. Playing and loafing process. Geometry of planing and slotting cutters. Cutting cuts during planing and dumping, their features. Determining the strength and power of cutting during planing and dumping. Rationing of planing work. Safety. The varieties of planing and slotting machines, their kinematics. Main nodes and kinematic scheme. Topic 3.4. Drilling, coinening and deployment applied tool and machine tools features drilling process, coinening and deployment; movements when drilling, cencing and deployment; varieties of drills, centers and sweeps; elements of the design of drills, centers and sweeps; Calculation of cutting modes when drilling, coinkering and deployment; varieties of drilling and boring machines, the principle of their work; To be able to: choose a cutting tool and determine the optimal cutting mode during planing for the specified processing conditions; determine the main technological time during planing; choose a cutting tool for the production of holes; determine the depth, feed, the speed of rotation of the drill, zenker and sweep; determine the main technological time when drilling, cencing, deployment; make a kinematic balance equation for various kinematic chains of planing, drilling, boring machines; Determine the geometric parameters of the drill, centers, sweeps. The process of drilling, coinening and deployment. Main movements

15 Features of processes. Elements of the designs of drills, centers and sweeps, geometric parameters. Features of the elements of the design of the tools. Forces acting on the drill, torque. Sequence of calculating cutting modes when drilling, coinkering and deployment. Varieties of drilling and boring machines. Appointment, characteristics, main nodes, kinematic scheme, work performed. Practical work 6 Measurement of geometric parameters of drills, centers and sweeps. Independent work of students to prepare a presentation, find videos Topic 3.5. Milling, applied tool and machines Features of the milling process; Milling assignment; varieties, design cutters and their geometry; types of milling; types of milling machines and their designation; appointment of dividing heads; be able to: choose a mill and determine the optimal cutting mode during milling for the specified processing conditions; determine the main technological time in cylindrical and either milling; perform the setting of the kinematic chain of the milling machine; Select the type of milling machine for the specified processing conditions; Adjust the kinematic chain of the divisory head of the milling machine for the specified working conditions. Milling process. Purpose, varieties, design and geometric parameters cutters. Features of the milling process. Cutting schemes during milling. Forces acting on the mill. Features of overtime milling. Milling operations. Milling machines. Their appointment and scope. Horizontal fiber, vertically milling, longitudinal milling, carouselnofreve, copy mills. Movement in the machines. Main nodes and kinematic schemes. Sealing heads, their types and device. Setting the dividious head to various types of work. Practical work 7 15

16 16 Studying the milling process. Topic 3.6. Dental, threads, applied tools and machines Features of copying methods, running and rolling the toothed surface; Design elements of the tap and dice; Design elements of disc modular, worm cutters; Principle of operation of chub processing and threaded machines; To be able to: choose a cutting tool and determine the optimal cutting mode for a specific type of processing of the toothed and threaded surface; Make the equation of the kinematic balance for various kinematic chains of chub and threaded machines. Methods of cutting gear surfaces. Copying tools that run by the copy method: disc and end modular cutters, headband heads, scope of their application. Sound cutting tools working according to the routing method. Tools for cutting cylindrical wheels: Seabed combs, worm modular cutters, teubrous dol robies, shevers. Tools for cutting conical wheels: paired planer cutters, paired cutters, cutting heads. Cherry Wheel Treatment Tools: Worm cutters, worm shevers. Basic information on toothing. The process of threading. Methods for formation of thread and thread-cutting tools: taps and dies, machine-manual taps, hand taps, wrenchers, thread-cutting cutters and combs, comb cutters, grinding circles. Elements of cutting mode when insulating and threading. General information about threading. Discovering and threading machines. Their classification. Seet-cutting machine, shocking machine. Thread-cutting machine. Practical work 8 Studying tools for cutting gear beams. Practical work 9 Studying tools for threading. Independent work of students

17 17 Prepare a presentation, find videos Topic 3.7. Stretching, applied tool and machines Cutting tool and optimal cutting mode while stretching for the specified processing conditions; Technological capabilities of an extended machine. The process of stretching, its features and scope. Classification of broach, structural elements and geometric parameters of broke. Stretching schemes. Firmware, its difference from the broach. Regulation of work during stretching. Appointment and types of outstanding machines, their use. Kinematics, hydraulic engineering and the principle of the expanted horizontal machine. Topic 3.8. Grinding, applied tool and machines Features of grinding process; various types of grinding, their use; classification of grinding machines, the principle of their work; varieties of grinding machines, the principle of their work, the device; Varieties of finishing machines, their appointment and the principle of their work. Grinding process, its features and scope. Characteristics of the abrasive tool, classification of abrasive materials. The main types of grinding, cutting mode with flat grinding. Honing process. Grinding machines, their classification. PlaneShlylifers, round-chlorinous, powerless-fluffy, intra-gland furnace machines, their main nodes, purpose, hydracetic scheme of machine tools. Main nodes, principle of operation. Contracting machines. Movement in the machines. The device of honing heads. Prior stools, work on them. Superfining essence. Practical work 10 Studying grinding process.

18 18 Topic 3.9. The basics of automation of metal-cutting machines have a representation: about automatic lines and CNC machines. The main directions of automation of metal cutting machines. Automatic streams, processing centers. Independent work of students to prepare a presentation, find video theme of the methods of electrochemical processing of metals, radiation processing methods have a representation: about electrochemical methods of processing materials; Essence of electrical processing of materials. Essence of methods. Electrochemical polishing Method of processing electronic and light beam. Practical work 11 Electrochemical processing of metals. and grinding. Section 4 Production of typical parts on machines Topic 4.1 Processing of outer surfaces of rotation Technical requirements for shafts; Billets used for the manufacture of shafts; Typical technological process of manufacturing shafts. Constructive shapes of shafts. Technical requirements for shafts. Preparation of shaft blanks to machining. Typical technological process of processing stepped and smooth shaft.

19 Practical work 12 Typical technological process of processing a stepped and smooth shaft. Topic 4.2. Processing of internal surfaces of rotation Technical requirements for bushings; Billets used for the manufacture of sleeves; Typical technological process of manufacture of sleeves. Characteristics of holes in the method of their processing. Requirements for holes. Typical technological process of manufacture of sleeves. Practical work 13 Typical technological process of manufacturing sleeves. Topic 4.3. Processing of planes, grooves, shaped surfaces. Technical requirements for cabinet parts; billets used for the manufacture of cabinet parts; Typical technological process of manufacturing cabinet parts; To be able to: choose a blank for cabinet parts; Make a list of operations, choose a cutting tool and equipment for processing cabinet parts. Basic requirements for plane details. Choosing a method for processing flat surfaces. Typical technological process of manufacturing cabinet parts. Practical work 14 Typical technological process of manufacturing cabinet parts. Topic 4.4. Processing of threaded and gear surfaces. Technical requirements for gear wheels and threaded parts; nineteen

20 blanks used for the manufacture of gears and threaded parts; Typical technological process of making gears and threaded parts. Requirements for gear wheels and threaded surfaces. Selecting a gear surface treatment method. Choosing a method for processing a threaded surface. Typical technological process of making gear wheels. Practical work 15 Typical technological process of making gear wheels Independent work of students to prepare a presentation, find videos test work. Start. twenty

21 21 Listing Literature Main: 1 Nikitenko V.M. Technological processes in mechanical engineering. Ulyanovsk: ULGTU, C 2 Materials Science and Technology of Metals: Textbook for universities / ed. Silman G.P. and others. -2th ed., Pererab. and add. -M.: Higher School, Cupacam B.I. Metal cutting machines. M.: Publishing Center "Academy", p. Additional: 1. Chernov N.N. Technological equipment (metal cutting machines). Tutorial M.: Mechanical Engineering, p.


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Ministry of Education and Science of Russia Federal State Budgetary Educational Institution of Higher Education "Voronezh State University" Borisoglebsky Branch (BF FGBOU VSU) Approve Dean

Ministry of Education of the Irkutsk Region of the GBPOUIO "Irkutsk Aviation Technical School" argue the deputy. Director for Ur Koroshkova E.A. "3" August 205. Calendar-thematic plan for 205-206 academic year

"I argue" Rector of the University of A. V. Lamatheev "19" 09 2007. Technology of structural materials Cutting tools and its main elements and geometry Methodical instructions for the implementation of laboratory

Committee of Educational EAO Regional State Professional Educational Budgetary Institution "Polytechnic Technical Academy" reviewed at a meeting of PCC approved deputy. ODO directors (protocol

Public Joint-Stock Company KAMAZ Repair and Instrumental Plant Manufacturing Tool 2017 Drills Spiral Drills Auned Drills With Thickened Core Drill Tool Drills Spiral

Ministry of Education and Science of the Russian Federation Federal State Budgetary Educational Institution of Higher Professional Education "Kuban State University" Branch

Technological processes of mechanical processing of typical parts ... 8 Production of axes and shafts ... 8 Billets and methods for fixing ... 8 Main options for manufacturing axes and shafts ... 9 Choosing equipment

In addition to the above methods of processing metals and manufacturing billets and machine parts, other relatively new and very progressive methods are used.

Metal welding. Until the invention of metal welding production, such as boilers, metal buildings of ships or other works requiring compounds with each other of metal sheets, was based on the use of the method clap.

Currently, the clap is almost not used, it was replaced metal welding. The welded connection is more reliable, easier, produced faster and allows you to save metal. Welders require less labor costs. Welding can also be connected to parts of the broken parts and by welding metal to restore worn out parts of the machines.

There are two ways of welding: gas (autogenic) - with a combustible gas (a mixture of acetylene and oxygen), which gives a very hot flame (over 3000 ° C), and electric welding,at which the metal is melted with an electric arc (temperature up to 6000 ° C). The greatest application currently has an electric welding, with which the small and large metal parts are firmly connected to each other (weld with each other part of the buildings of the largest sea ships, bridge farms and other building structures, parts of huge boilers of the highest pressure, machine parts, etc. ). The weight of the welded parts in many machines is currently 50-80% of their total weight.

The traditional processing of metal cutting is achieved by removing chips from the surface of the workpiece. In the chips goes up to 30-40% of the metal, which is very uneconomical. Therefore, increasing attention is paid to new methods of processing metals based on waste-free or low-waste technology. The emergence of new methods is also due to the propagation of high-strength, corrosive and heat-resistant metals and alloys, the treatment of which is difficult for conventional methods.

New metals processing methods include chemical, electrical, plasma-laser, ultrasound, hydroplastic.

For chemical processingchemical energy is used. Removal of a certain metal layer is carried out in a chemically active medium (chemical milling). It consists in taking time and the place of dissolution of the metal from the surface of the blanks by etching them into acidic and alkaline baths. At the same time, the surface not to be processed is protected by chemically resistant coatings (varnishes, paints, etc.). The constancy of the etching rate is maintained due to the constant concentration of the solution.

Chemical methods of processing are obtained by local refinery on non-rigid blanks, rigidity ribs; winding grooves and gaps; "Waffle" surfaces; Processing surfaces, hard to reach a cutting tool.

For electric methodelectrical energy is converted to thermal, chemical and other types of energy directly during the removal of the specified layer. In accordance with this, electrical processing methods are separated into electrochemical, electric-product, electrical thermal and electromechanical.

Electrochemical treatmentbased on the laws of anodic dissolution of the metal under electrolysis. When the DC pass through the electrolyte on the surface of the workpiece included in the electrical circuit and is an anode, a chemical reaction occurs, and compounds that are transmitted to the solution are formed or are easily removed by mechanical manner. Electrochemical processing is used for polishing, dimensional processing, honing, grinding, metal cleaning from oxides, rust.

Anode-mechanical processing Combines electrothermal and electromechanical processes and occupies an intermediate place between electrochemical and electro-erosion methods. The processed workpiece is connected to the anode, and the tool to the cathode. Metal discs, cylinders, ribbons, wires are used as a tool. Processing is carried out in an electrolyte environment. The workpiece and tool set the same movements as with conventional mechanical processing methods.

When the direct current is passed through the electrolyte, the anode dissolution of the metal is processed as with electrochemical processing. When contacting the tool (cathode) with the micronether of the processed surface of the workpiece (anode), the process of electroerosia occurs inherent in the electric check processing. Electroeration and anode dissolution products are removed from the processing zone when the tool and blanks are moving.

Electroerosion treatment Based on the laws of erosion (destruction) of electrodes from conductive materials when passing the pulse electric current between them. It is used to flash cavities and holes of any shape, cutting, grinding, engraving, draining and hardening the tool. Depending on the parameters of the pulses and the species used to obtain the generators, the electro-erosive treatment is divided into electric spacing, electrical and electrocontact.

Electrical viewing Apply for the manufacture of stamps, molds, cutting tools and to harden the surface layer of parts.

Electropulse processing It is used as a preliminary in the manufacture of stamps, turbine blades, surfaces of the shaped holes in the details of heat-resistant steels. In this process, the speed of removal of the metal is about ten times more than during electrical check processing.

Electro-contact treatment Based on the local heating of the workpiece at the point of contact with the electrode (tool) and the removal from the processing zone of the molten metal mechanically. The method does not provide high accuracy and quality of the surface of the parts, but gives a high speed of removal of metal, therefore it is used when stripping a low tide or rolled from special alloys, grinding (roughing) cabinet parts of machines from hard-made alloys.

Electromechanical processing Related to the mechanical action of electric current. This is based, for example, electro-hydraulic treatment that uses the effect of shock waves resulting from a pulsed breakdown of a liquid medium.

Ultrasonic processing of metals- A variation of machining is based on the destruction of the material being processed by abrasive grains under the tool blows, fluctuating with an ultrasonic frequency. Energy source serve electrosal current generators with a frequency of 16-30 kHz. The Punson's working tool is fixed on the current generator waveguide. Under Punson, the workpiece is installed, and a suspension consists of water and abrasive material comes into the processing zone. The processing process is that the tool, hesitating with an ultrasonic frequency, hits the abrasive grains that are cleaned particles of the workpiece material. Ultrasonic processing is used to produce carbide liners, matrices and punches, cutting figured cavities and holes in detail, firmware of holes with curvilinear axes, engraving, cutting threads, cutting blanks to pieces, etc.

Plasma-laser methodstreatments are based on the use of the focused beam (electron, coherent, ion) with a very high energy density. The laser beam is used as a means of heating and softening the metal ahead of the cutter and to perform the immediate process of cutting during the firmware of holes, milling and cutting sheet metal, plastics and other materials.

The cutting process goes without the formation of chips, and the metal evaporated due to high temperatures is carried out with compressed air. Lasers are used for welding, surfacing and cutting in cases where enhanced requirements are presented to the quality of these operations. For example, the laser beam will cut superhard alloys, titanium panels in rocket lights, products from nylon, etc.

Hydroplastic treatment Metals are used in the manufacture of hollow parts with a smooth surface and low tolerances (hydraulic cylinders, plungers, carriage axes, electric motors, etc.). The hollow cylindrical workpiece heated to the temperature of the plastic deformation is placed in a massive detachable matrix made in the form of a manufactured part, and is pumped under pressure water. The billet is distributed and takes the form of the matrix. Details made in this way have a higher durability.

New methods of metal processing are derived from the manufacture of parts to a qualitatively higher level compared to traditional technology.

Under metalworking, the technological process of changes in forms, qualitative characteristics and mechanical properties of steels and other materials to achieve the necessary indicators is implied. Modern technologies for processing solid and superterald blanks make it possible to produce exceptional quality products at minimum production costs.

With all this, the industry continues to steadily evolve. To date, you can allocate 3 key areas In the development of metalworking:

  • development of new alloys and materials for their processing;
  • improving the efficiency and productivity of the process;
  • optimization of metalworking methods.

Metal processing technologies

All metalworking technologies can be divided into 4 categories:

    A significant proportion of metal products is made by casting molten steel, cast iron, bronze, aluminum, copper, magnesium, zinc in special forms. This method is used for the production of heating radiators, pumps and gearboxes, production machines. In the overwhelming majority of cases, the process of casting is accompanied by milling and boring processing of workers and clamping surfaces.

    Pressure treatment

    This group of metalworking methods include: pressing, rental, stamping, drawing, forging. As a rule, the exposure to pressure is directed to the change in the shape and size of the metal blank without the destruction of its properties and structure. However, before applying any mechanical efforts, it is often necessary to increase the plasticity of the metal. This can be done by heating to certain temperature indicators determined by its chemical service.

    Ski technology is used to produce indefinite compounds. The essence of the method consists in heating the metal to the melting point. To date, 6 types of welding are distinguished:

    • chemical;
    • thermal;
    • gas;
    • electric;
    • arc;
    • contact.

  1. Mechanical processing on metal machines

    For the manufacture of parts of the required geometric shapes and sizes, the technology of cutting of metals on special machine equipment is used for pre-designed drawings. To date, this is the most common version of the processing of steel, copper, brass, gold, silver, etc. Metal cutting include turning, milling, engraving, planing and grinding machines.

    For the processing of thin metal metals, laser cutting technology is used. The optical laser beam burns out the metal along the predetermined cutting line. This method allows you to perform high-precision processing.

    Another method of modern metalworking metals is hydroabrasive cutting. Its principle is to effect on the workpiece of thin water jet with particles of abrasives. Water is supplied under high pressure, due to which abrasive substances are literally destroying the material in the exposure zone. Hydroabrasive cutting is widely used in those enterprises where safety equipment prohibits strong heating and the formation of sparks.

    Finally, one of the safest and high-speed methods of cutting metal is plasma cutting. It allows you to accurately clean the rental of any thickness at any angle. Plasma is formed from gas with the participation of electric current. The temperature of such a jet can reach 30,000 degrees. Plasma cutting is suitable for processing any metals: non-ferrous, black, refractory.

16 Sep 2017. Suhih Victor

Despite the emergence of new innovative materials, the metal remains the basis of industry and construction. New engineering technologies allow you to develop new methods of processing metals, which is the main task of technologists and designers. Processing of metals according to new technologies is carried out in order to improve the quality, increase the accuracy of processing, performance and reduction of waste.

The three main directions of metal processing are distinguished:

  • Formation with the help of high-precision plastic deformation methods.
  • The use of traditional methods for processing metals, but characterized by increased accuracy and performance.
  • Use of high-energy methods.

The choice of the optimal method of processing metals is determined by production requirements and production scholars. For example, very severe equipment designs cause increased energy consumption, and the reduced accuracy of the manufacture of individual parts and nodes is low performance of technology. Some technologies cannot provide the necessary strength properties and a metal microstructure, which ultimately affects the durability and durability of parts, even be made with minimal tolerances. The new metal processing technology is based on the use of non-traditional energy sources that provide its dimensional melting, evaporation or formation.

Mechanical processing of metal associated with the removal of chips is developing in the direction of the manufacture of particularly high-precision products predominantly in small-scale production. Therefore, traditional machines are inferior to the place of promptly overvollable metalworking complexes with CNC (numeric software control). Numerical software management - a machine operating on numerical control, is able to make certain actions that are specified using a special program. The operation parameters of the machine are set through numbers and mathematical formulas, after that it performs work according to the specified program requirements. The program can set parameters such as:

  • power;
  • work speed;
  • acceleration;
  • rotation and more.

A relatively low factor of using the material (during machining it rarely when it exceeds 70 ... 80%) is compensated by minimal tolerances and high quality of the finish surface of the products.

Manufacturers of systems with numerical management make the focus on the extended technological capabilities of the equipment under consideration, the use of modern high-resistant tool steels and the exclusion of manual labor operator. All preparatory and final operations on such complexes performs robotics.

Energy-saving methods of plastic deformation of metals

Metal processing technology, except for an increased metal utilization factor, has other essential advantages:

  • As a result of plastic deformation, the macro and microstructure of the product is improved;
  • The performance of equipment for stamping at times exceeds the same indicator for metal cutting machines;
  • After pressure treatment, the strength of the metal is increased, its resistance from dynamic and shock loads increases.

Progressive processes of cold and half-blood stamping - perfside, accurate cutting, extrusion, ultrasound treatment, stamping in a state of superplasticity, liquid stamping. Many of them are implemented on automated equipment equipped with computer monitoring and control systems. The accuracy of the manufacture of stamped products in many cases does not require subsequent adjustment - editing, grinding, etc.

High-energy methods for forming metals

High-energy metal processing technologies are used in cases where traditional methods change the shape and dimensions of the metal blank.

At the same time, four types of energy are used:

  • Hydraulic - fluid pressure, or individual items given by it in motion.
  • Electrical, in which all the processes of membrane are performed using a discharge - arc or spark.
  • Electromagnetic, implementing the processing of metals when exposed to the harvesting of an electromagnetic field.
  • Electrophysical, acting on the surface directional laser beam.

There are also successfully combined methods for the impact on the metal, in which two or more energy sources are used.

Hydroabrasive processing of metals Based on the surface effects of high pressure fluid. Such installations are used, mainly in order to improve the quality of the surface, removal of micronether, cleaning the surface from rust, scale, etc. In this case, the fluid stream can affect the product both directly and through the abrasive components in the stream. The abrasive material contained in the emulsion is constantly updated to ensure the stability of the resulting results.


- The process of measuring destruction (erosion) of the metal surface when exposed to a pulsed, spark or arc discharge on it. The high density of the volume thermal power of the source leads to the dimensional melting of the metal microparticles, followed by the removal of them from the processing zone of the dielectric work medium (oil, emulsion). Since when processing the metal, the processes of local heating of the surface are simultaneously occurring to very high temperatures, as a result, the hardness of the part in the processing zone is significantly increased.


It is that the processed product is placed in a powerful electromagnetic field, the power lines of which affect the workpiece placed in the dielectric. In this way, molding of low-plastic alloys (for example, titanium or beryllium), as well as sheet steel blanks are made. Similarly, ultrasound waves generated by magnetostriction or piezoelectric frequency converters are also on the surface. High-frequency oscillations are also used for surface heat treatment of metals.


The most concentrated source of thermal energy is the laser. - the only way to prepare in the blanks of ultra-low holes of increased dimensional accuracy. Due to the direction of thermal action of the laser for metal, the last in the adjacent zones is intensively reinforced. The laser beam is able to produce a dimensional firmware of such refractory chemical elements, like tungsten or molybdenum.


- An example of a combined effect on the surface with chemical reactions arising from the passage through the workpiece of the electric current. As a result, the surface layer is saturated with compounds that can be formed only at elevated temperatures: carbides, nitrides, sulphides. Superficial coating of other metals can be performed by such technologies, which is used to produce bimetallic parts and nodes (plates, radiators, etc.).


Modern metal processing technologies are continuously improved using the newest achievements of science and technology.