A list of the main operational and morphological properties of heat and sound insulating materials (HSIM) is selected, which makes it possible to improve the energy efficiency of production and working conditions for personnel in press and heat-treating shops. From the list properties, taking into account the range of changes in their values, classification codes are formed. The code system is used to form a task for the selection of HSIM, displaying the priority, composition and values of the operational properties required to solve a specific problem of heat and sound insulation design. The structure of the HSIM database is formed as a multi-level table, the inputs of which are also codes of operational and morphological properties of HSIM. The selection of the HSIM required by the conditions of the design is carried out from the database using a specially developed algorithm.

The increase in the carrying capacity of KAMAZ vehicles necessitates the use of heavyduty hot-rolled thick-sheet rolled products made of microalloyed steels with a high yield strength for the production of sheet stamping. The development of the production of such parts faces problems of ensuring stampability, which requires finding ways to increase it both in the metallurgical and machine-building processing of rolled products. Based on expert assessments of specialists, generalization of production experience, modeling of plastic flow in sheet stamping operations, field experiments, the thinning deformations responsible for the appearance of defective signs (cracks excessive refinement) in stamped parts are estimated. The influence of the parameters of the processed material, workpiece, technology on the deformation of thinning is established, the directions of increasing the stampability on a specific part “Bracket” are shown.

The use of microalloyed dispersion-hardening steels allows not only to save expensive alloying elements, but also leads to significant energy savings due to the possibility of using controlled cooling of steel semi-finished products directly after hot forming. The purpose of the research carried out in this work was to determine the rational modes of controlled cooling of forgings made of dispersion-hardening steels that provide the properties and microstructure required by the standard. For this purpose, a simulation simulation of the cooling of the forgings of the connecting rod of the KAMAZ car engine with the temperatures of the stamping end in various media (compressed air, water-air mixture, water, oil) was carried out, which made it possible to determine the composition of the medium (ratio) of water and air in the water-air environment and its supply modes providing cooling of forgings with speeds above critical, that is, without the formation of a ferritic mesh along grain boundaries during the decay of austenite. Subsequently, these modes were reproduced in laboratory and experimental-industrial conditions with the determination of the mechanical properties and microstructure of the steel of the connecting rod forgings. For 38MnVS6 steel, it has been established that controlled cooling from the stamping end temperatures not lower than 950 °C and the cooling rate not lower than 10 °C/sec, the properties and microstructure of forgings meet the requirements of the standard for connecting rods. This makes it possible to abandon the energy-intensive heat treatment (thermal improvement) of forgings provided for by the production technology.

The surface layer after chemical-thermal treatment in structure and physico-mechanical properties differs sharply from the inner layers of the product, which leads to significant internal stresses that cause deformation and warping, i.e. resizing and shape. Prediction of the phase composition, depth of carbon saturation of the layer, microhardness and deformation of the surface of the product elements after chemical-thermal treatment based on modeling in the application package allows even at the stage of technological preparation for the production of precision hot die forging to make adjustments to the geometry of the die tool to increase dimensional accuracy, and accordingly, the durability of the gear ring gears. The input data for modeling the processes of chemical-thermal treatment is a 3D model of the product with a finite element grid and the fixation scheme of the product, temperature and time modes (heating temperature, heating and cooling rate, holding time, number of cycles), type of carburizing cooling medium and its temperature, material details.

The main factors that determine the accuracy and quality of the ring gear during precision calibration are described. The corresponding ACS (automated control system) schemes are proposed.

The procedure of automated process reliability evaluation is developed in order to prevent recurrent defects in parts manufactured by die stamping. The procedure is based on the analysis of such factors as part design, material, its mechanical and physical properties; equipment parameters, tool performance, etc. The list of reliability factors may vary according to type of operation as deformation process is different for each group of operations. The adjustment of stamping process reliability performance prevents any defects emerging during production of critical parts as early as the work preparation stage.

The main parameters of the technological process that have the greatest impact on the cost of forgings obtained by hot stamping are established

The dispersion of blank masses depending on the accuracy class of the initial metal rolling is estimated. The influence of the method of the initial blank segments on the stamping process is described.

The article highlights the main factors, defining the surface quality of ring gear during hot bulk precision stamping. It offers enhanced techniques of surface quality of stamped ring gear.

The article deals with the possibility of using an intelligent control system for the parameters of the technological process of precision stamping and mechanisms of crank hot-stamping presses.

For cylindrical and annular workpieces, a method is proposed for increasing the precision obtained in cold deformation on the basis of plane finishing. Modeling results are presented. The stress–strain state of the workpiece in upsetting is determined.

Baushinger's effect is one of fundamental polycrystalline metals properties shown in under-voltage of a plastic metal current when changing a sign of deformation for opposite. For this phenomenon research during the intensive plastic deformation (IPD) occurring in cyclically repeating processes of direct and return extrusion imitating modeling in the environment the QForm was used. As a result of modeling it is established that in the specified material cell in deformation center big consecutive cycles of stretching compression (0,5-0,7 for a cycle) and (4-7 for all process) take place - stretchings, etc. depending on quantity of cycles' technological influence. The technological scheme of deformation offered in work allows accumulating the considerable deformations leading to essential crushing of a microstructure up to the nanosizes. Baushinger's effect which is shown at such scheme of deformation leads to decrease in level of peening that allows carrying out deformation with the smaller force under conditions of cold deformation without metal destruction. Practical application of this process is expedient in production of high-strength products from thermally weak or non-strengthened metals and alloys, in particular aluminum.

The significance matrix for the parameters of “material-billet-equipment-process-tool-personnel-environment” system was compiled using the systems approach to the assurance of forging dimensional accuracy, and the expert analysis revealed the most significant process parameters that affect the accuracy. The application of simulation modeling helped to establish the dependence of forging force on the dimensions of an incoming billet. The paper suggests a solution to increase the accuracy of the sized forgings.

The procedure of automated process reliability evaluation was developed in order to prevent recurrent defects in parts manufactured by die stamping. The procedure is based on the analysis of such factors as part design, material, its mechanical and physical properties; equipment parameters, tool performance, etc. The list of reliability factors may vary according to a type of operation as deformation process is different for each group of operations. The adjustment of stamping process reliability performance prevents any defects emerging during production of critical parts as early as the PPE stage. The automated control system for IE design at the PPE stage provides better part quality and lower production expenses thanks to IP reliability.

Key parameters influencing the deformation force, intensity ofplastic deformation and its distribution at IPDmultipleextrusion are considered, recommendations about a choice of rational parameters are made.

The paper presents the results of a comparative tribological study of structural steels with a carbon content of 0.1% and 0.45%. The following thee conditions are studied: initial (hot rolled), after heat treatment (improvement) and after improvement with subsequent severe plastic deformation (SPD) processing by equal-channel angular pressing (ECAP). It is established that the materials after different types of processing have different structural states, and demonstrate different shear strength of adhesive bonds and adhesion (molecular) components of the friction coefficient in contact with the tool steel of the R18 type. At the same time, it is revealed that the greatest effect of hardening due to microstructure refinement is observed on the specimens of low-carbon steel. Medium-carbon steel after SPD processing has approximately the same tribological properties as after heat treatment.

An automated technique for the technological process reliability evaluation is supplemented with an improvement stage to provide the quality of complexly shaped machine elements manufactured by the sheet stamping. As a result, there is a possibility to expediently develop and realize measures for the structural improvement of an element manufactured by stamping in cases using CAE software, when technological process correction does not provide conditions for defectfree stamping.

Using the hypothesis of damage summation and the linear law the accumulation of such a method is proposed for predicting the fracture with large plastic deformation.

Proposals are made regarding the design and manufacture of a composite rod-type hole-punching tool by plastic deformation.