Industrial robots are used for machining in mechanical engineering. This trend is associated with an increase in the geomet-ric complexity of parts and wider kinematic capabilities of industrial robots in comparison with classical CNC machines. The article analyzes the technological capabilities of using industrial robots in finishing machining operations, and pro-vides the reasons for limited robots introduction Schemes of construction of technological operations are given: "part in hand" and "tool in hand". The factors influencing the choice of the preferred machining are studied. The areas of effective application of passive and active adaptation tools are given. The article provides two main reasons for possible vibrations under robotic manipulation: e.g. low rigidity of the industrial robot structure and shape errors effect in the previous opera-tion. The problem of developing a sustainable code conversion for the amount of material removal is discussed. The problem statement is due to the fact that the model of the cutting process varies greatly depending on the cutting conditions. Force control work makes it possible to take into account the rigidity of the robot without sacrificing the running accuracy in six coordinates. The article discusses the use of a neural network and a genetic algorithm in the development of a robotic pol-ishing operation for a flat surface within limited access constraints. The authors of the article have developed a postproces-sor for controlling an industrial robot in case of variable tool overhang and uneven tolerance. Special technological equipment has been designed and manufactured for this purpose. Experiments on testing of the developed algorithmic and software have been conducted in the laboratory "Industrial Robots and Automation Tools"

Additive technologies exemplified well in the industry. As a rule, it is technologies called synthesis on a support material (selective laser melting and the like), that make it possible to create products with complex geometries, internal channels, etc Modern software allows significant expansion in the capabilities of such technologies. One of the directions of the development in this area is the generative artificial intelligence, for example, in case of topological optimization aimed at reducing the weight of the product without loss of strength characteristics. It is based on well-known mathematical models and numerical calculation methods. At the same time, it has now become possible to calculate several models in parallel, depending on the set parameters. At the moment, several algorithms are used for modeling and calculations, gaining the reputation of good results, but at the same time an additional verification of the results obtained before manufacturing, is required. This paper presents the main mathematical models and examines the features for optimization in additive technologies. It discusses examples of model combinations. Using the example of a promising optimization method, the existing limitations and the possibilities of overcoming them are studied. Due to the peculiarities of modeling, one of the tasks is to obtain the results closest to the real ones, therefore, an option for improving the work is proposed, taking into account the real values of experiments. A pattern to understand the specifics of the work of various methods is given, allowing a possible data calculation option depending on the available initial conditions.

The basics of the design of rotary kilns, widely used in the processing and preparation of various raw materials, are described. It is shown that the weak point of the rotary kilns design is the support rollers, which carry the entire load of the kiln and are initially made of less durable steel than a bandage being in contact with them. In fact, the design itself provides for the possibility of periodic replacement of the «miscellaneous part», which is a support roller. However, for an operator, any downtime of equipment leads to economic losses. Therefore, the goal has been formulated: to increase the durability of the support rollers avoiding a significant change in the kiln design. For this purpose, initially, from the point of view of contact mechanics, the basics of the interaction of the surfaces of the support roller and the bandage of a rotary kiln have been studied. Calculation models for various contact options of these parts have been given. The force model of contact between the surfaces of the support roller and the bandage has been studied. The maximum normal and tangential stresses in the contact zone, at its boundary and beyond have been determined. At the same time, complex processes occur in the contact area of the roller and the bandage surfaces, in particular, micro-slipping and sliding, due to the difference in the diameters of the rotating bodies and the difference in the level of their mechanical properties. Micro-slip is one of the sources of fretting wear. However, the most significant wear occurs as a result of mechanical interaction and changes in the structure of the surface layer with the gradual accumulation of various kinds of defects in the crystalline structure caused by plastic deformation of the surface layer of the contacting parts. It is shown that not only the mechanical and operational properties of the material for their construction, but also the displacement of the contact spot during kiln operation have a significant effect on the wear process of the support rollers. The displacement can be angular or linear, and in real conditions it is most often combined, it is caused by the thermal expansion / compression of the metal structure and the operating conditions of the rotary kiln.

In hammer mills, fuel is ground by the impact of the beaters on the coal pieces entering the mill, as well as by the abrasive action of the beaters on the coal in the space between the beaters and the mill body. A disadvantage of hammer mills is the rapid wear of the beaters, requiring their frequent replacement. It is known that the greater the mass of the material being worn, the longer the beater can work, all other things being equal. The mass of the metal being worn can be increased by increasing the mass of the beater itself or the degree of metal utilization. As practice shows, increasing both has its limits. The optimal mass of the beater for medium-capacity mills with a diameter of up to 1,6 m is 8…10 kg, for high-capacity mills with a rotor diameter of 2…2,5 m, the optimal mass of the beater is 12…14 kg. Increasing the mass of the beater beyond these values does not lead to a significant increase in the service life of the beaters, since this reduces the degree of metal utilization. In addition, replacing beaters weighing more than 14 kg significantly increases the labor intensity of beater replacement operations. The paper investigates the dependence of specific beater wear on the angle of impact with the crushed material and shows the sequence of changes in the shape of the working surface of the beaters. The abrasion of the beaters at different angles of attack of abrasive coal particles is considered, the particle ejection velocity from the working element is calculated, and a mathematical model of the forces arising during the working movement of the beaters is compiled. A methodology for designing the geometric shape of the working element of a tangential hammer mill – a beater – has been developed, which allows for ensuring stable mill efficiency due to uniform wear of the striking part of the beater while maintaining its effective working area.

This study examines the surface topography and wear mechanisms of polymer matrix friction composites used in brake pads. By analyzing microscopic images and three-dimensional surface wear profiles, the study identifies key wear processes and the formation of third body particles that influence the behavior of friction. The research used samples prepared by traditional methods of powder metallurgy based on phenol-formaldehyde. The experiments included friction tests under various conditions, and the results evidentiated distinct phases in the variation of friction coefficient, being illustrative of the composite's response to various stresses. The morphology of the surface after testing revealed several wear mechanisms, including abrasive and adhesive wear.

The paper states the need to identify a processing method through which increased operational properties in the work material can be obtained within a single process step. To solve the raised problem, the use of wave strain hardening (WSH) technology is proposed. The peculiarity of the technology lies in the possibility of simultaneous control of a number of technological parameters and the effect on the processed material of prolonged shock pulses characterized by the transfer of impact energy to the deformation site of more than 65%. Due to the presence of a large number of controlled process variables, the WSH allows fine adjusting of the uniformity of hardening and forming hardened areas at a depth of up to 15 mm. Due to the fine adjustment of the uniformity of hardening it becomes possible to avoid the formation of excessive cold work hardening of the surface layer and it makes great difference between WSH and other dynamic methods of surface plastic deformation, for example, stamping. With uneven hardening of WSH, solid and viscous regions take regular turns in the surface layer, forming a heterogeneous structure. The analysis of literature sources has shown that the presence of such areas in the surface layer makes it promising for purposes of operational properties improvement. The paper presents the results of experimental studies of the effect of the heterogeneous structure created by WSH on the operational properties: resistance to contact staining; cyclic strength under alternating loads, corrosion resistance. Laboratory studies of operational properties were carried out both using production equipment and specially designed facilities. The results obtained indicate the prospects of using WSH for operational properties increase and the existence of a "universal" operation mode.

The experimental and theoretical foundations of the material science approach to the assessment of lubricants are described. This approach is based on the analysis of the complex of structurally sensitive properties of antifriction material in the tribodeformation zone and aimed at identifying the significant role in the process of interaction of lubricants with the friction surface. The rheological properties of the surface layer formed in the tribo material under conditions of contact deformation and by the action of a lubricating medium determine the conditions for the formation of a wear-resistant structure. The concepts of the physical-chemical bases of the action of the medium in relation to the problems of elasticity and sliding contact are formulated, describing the behavior of surface-modified materials in the simplest stress-strain states. It is shown that when a surface-hardened material, the residual stresses within external layer are in agreement with the loading stresses, while in the inner volume zone they are opposite to them. The distribution of residual stresses in a surface-hardened sample turns out to be the reverse of the case of a plasticized material. The distribution of residual stresses in a surface-hardened sample turns out to be the reverse of the case of a plasticized material. Schematic diagrams of residual stresses arising in the near-surface formation of the material as a result of its elastic-plastic deformation during tribocontact action in a surface-plasticizing and surface-hardening lubricating medium, are presented. It is shown that in the surface-plasticized near-surface formation, residual stresses are compressive in nature, and in the surface-hardened layer they are tensile. There is a sharp change in the direction of residual stresses between layers at their boundary. The stress distribution over the depth of the material is qualitatively similar to the corresponding schematic diagrams obtained for cases of torsion and bending. Based on the calculation of the diagrams of the components of the residual stress tensor arising in the surface layer of the antifriction material during sliding friction, the conditions for the implementation of the plasticizing and strengthening triboeffect, are shown. It is also shown that among industrial aluminum bronzes, BrA5, BrA7 have the highest wear resistance in surfactants.

The article views fundamentally different scientific approaches to the study and processes control for metallopolymer friction units tribocontacts and, separately, for metal ones. The article presents the developed criteria for the choice of fillers in the composite: for example, in antifriction interfaces, it is a mechanism that forms secondary structures (friction transfer films); in friction interfaces, it is the introduction of reinforcing elements into a polymer composite, that, as a result of friction, can penetrate into the metal counterbody and strengthen it. At the same time, the strength characteristics were evaluated by quantum chemical calculations and experimental confirmation by X-ray electron and Auger electron spectroscopy (AES) data. As for the wear resistance increase in metal-to–metal tribosystems by traditional methods – electric arc metallization, gas-flame coating, detonation-gas, plasma, etc., they do not properly ensure stable operations of tribosystems. Currently, the most promising techniques used for surface modification and hardening are vacuum ion-plasma technologies. The ideas of applying thin-film coatings are based on techniques based on both physical processes (physical vapor deposition with PVD coating) and chemical principles (chemical deposition from the gas phase – CVD process). The PVD- method involves the transfer of the coating material to a vaporous state, followed by its delivery to the sample and vapor deposition on it. When using CVD methods, the coating on the sample is transferred from carbonites, organometallics, etc. The paper presents the results of research for finding the dependence of the physico-mechanical and tribological properties of coatings –PVD, DLC, high-entropy or combined, on the technological parameters of application.

To meet the requirements affecting the quality of functional coatings, various technologies are currently being used, one of which is the use of ultrasonics. To form functional coatings, ultrasonics are used both at the stage of surface preparation and at the stage of coating deposition. Thus, at the stage of surface preparation, ultrasonics allow making surface preclean, ensuring the necessary surface roughness due to ultrasonic rolling, as well as preactivation of the surface before nitriding due to surface plastic deformation. In case of coating deposition, ultrasonics contribute to better nitriding and painting. However, ultrasonic equipment used in various preparation and coating deposition processes differs significantly in its characteristics. Thus, the ultrasonic generators vary in alternator capacity, specific material consumption, actual frequency, as well as design features that ensure stable operation, for example, automatic frequency control. The converters differ from each other in accomplishable amplitudes, power and actual frequency. In this regard, the aim of the work is to develop recommendations on the use of ultrasonic equipment in various technical processes for the creation of functional coatings. The paper studies ultrasonic equipment used in surface preparation and functional coating application process. The main process-dependent parameters aimed at choosing the required equipment have been characterized. Recommendations are given on the use of ultrasonic equipment for various functional coatings generation, when a converter-generator couple is found and it meets the requirements for most surface preparation and coating deposition processes.

The paper presents two main directions for improving the efficiency of permanent magnets (PM), by changing chemical composition of the future magnet and through variations of magnetic field shape. Increasing the efficiency of PM by changing chemical composition over the decades has made it possible to reduce multiply the size of the final product. In turn, increasing the efficiency of PM by alternating the magnetic field shape is a relatively new direction. Based on the analysis of the presented methods for increasing the efficiency of PM, it is proposed to use additive technologies, namely laser powder surfacing for the manufacture of permanent magnets. To conduct experimental studies, the KUKA robotic complex and permanent magnets are used as a source of a permanent magnetic field. The paper presents some modes of laser powder surfacing of Sm and Fe powders. A complex of six neodymium magnets is used to maintain a magnetostatic field. Strength distribution of the magnetizing field between the magnets and in the main working area is described. The external view and condition of the powders used for the manufacture of experimental samples are presented. Experimental samples and selective approach for analyzing the microstructure and concentration spectra of elements are described. The microstructure and distribution of elements in the obtained samples were studied depending on the texture of the sample relative to the magnetic field and laser surfacing mode. The effect of the applied organic binders on the microstructure and chemical composition has been determined. The distribution of elements in the samples and the transition layer between the support plate and the deposited metal is studied.