DEVELOPMENT AND COMMERCIAL IMPLEMENTATION OF HIGH PERFORMANCE MANUFACTURING AND ENVIRONMENTALLY APPROPRIATE TECHNOLOGY OF SURFACE PLASTIC DEFORMATION OF CARS PARTS

The article covers the foreign and domestic experience in development of dry processing technologies. The authors give the results of the introduction of dry processing technologies (cutting, turning, milling, drilling) on the manufacturing companies in Germany. The article presents the analysis of lubricoolants consumption carried out at the JSC "AVTOVAZ", and describes the negative impact of lubricoolants on the human organism and the environment. Possible pathways of lubricoolants components to the atmosphere and soil are described.

Lubricoolants, in most cases of technological process engineering, are considered to be the obligatory components. The authors described three basic missions of lubricoolants: cooling, lubrication, and chip clearance that are essential for steady process behaviour.

The article describes the influence of lubricoolants deletion from the treatment process. The authors compared the microrelief with the base and the proposed processing technologies and developed the phenomenological model of wear of tools made of polycrystalline material with a homogeneous structure when processed by surface plastic deformation. To exercise the stochastic nature of impact of tool roughness on its wear process, the algorithm of tool surface microgeometry forming was developed. While solving the problem of automation of determining the area of tool work surface wear the calculation algorithms and IZNOSOMER software were developed. The system has the advanced capabilities to create a user interface, a wide range of functions, methods, and properties necessary for solving applied computational and engineering challenges. The solutions obtained are based on the use of domestic technology and tools only, and allow rejecting the purchase of import equipment at the cost of up to EUR 1 million per unit, by increasing the loading of machine-building enterprises of the Russian Federation. Processing without lubricoolants technology eliminates the fire hazard from oil lubricoolants, environmental pollution and harm to human health.