This article presents ANSYS WB-based mathematical modelling of the thermofrictional milling process, which allowed studying the dynamics of thermal and physical processes occurring during the processing. The technique used also allows determination of the optimal cutting conditions of thermofrictional milling for processing various materials, in particular steel 40CN2MA, 30CGSA, 45, 3sp. In our study, from among a number of existing models of cutting fracture, we chose the criterion first proposed by prof. V. L. Kolmogorov. In order to increase the calculations performance, a mathematical model was proposed, that used only two objects: a parallelepiped-shaped workpiece and a cutting insert in the form of a pentagonal prism. In addition, the work takes into account the friction coefficient between a cutting insert and a workpiece taken equal to 0.4 mm. To determine the temperature in the subcontact layer of the workpiece, we introduced the coordinates of nine characteristic points with the same interval in the local coordinate system. As a result, the temperature values were obtained for different materials at the studied points during the cutter speed change. The research results showed the possibility of controlling thermal processes during processing by choosing the optimum cutting modes.

The authors developed the design of a special multi-blade rotary-friction tool. The multi-blade rotary-friction tool is equipped with two cupped cutters – heating and cutting. The heating cupped cutter is made of medium-carbon structural steel of any brand, and the cutting cupped cutter is made of steel R6M5. The final formation of the treated surface and its quality is provided by the cutting cupped cutter. This article presents the results of the calculation of the strength of the cutting cupped cutter multi-blade rotary friction tool. As a result, the following were established: when processing steels 30HGSA cutting force components reach the maximum value than when processing materials 40HN2MA, St.45, and St.3c (calm); strength and rigidity of the cutting cupped cutter is sufficient for processing optimal cutting conditions: nsp = 1000 rpm; S = 0.42 mm / rot; t = 1.0 mm.

This article presents the results of a study of the process of internal fluid leakage in the design of a gear pump with a biaxial connection. It is known that the volumetric efficiency mainly depends on the leakage of the working fluid through the gaps formed by the tooth heads and the pump casing, as well as between the end surfaces of the gears and the side walls of the casing. In addition, additional leaks occur along the contact line of the teeth. To reduce radial leaks, the gap between the gears and the pump casing is minimized, and to reduce end-leakage, the side walls are automatically pressed against the end surfaces of the gears by liquid under operating pressure. The design of the pump shows that the main internal fluid leaks occur in the gap between the gears and the housing. Naturally, these leaks require excessive energy consumption and, thereby, reduce the efficiency of the pump. The natural way to combat this circumstance is to reduce the marked gaps to a minimum. This is possible using an additional element - a biaxial sleeve. The dependence of the spring force on the fluid flow rate and the guaranteed gap between the ring gear and the pump casing has been analytically established. They are characterized by a drop in force with an increase in clearance and a rise in flow rate. This is due to an increase in the dynamic force in the gaps, which must be compensated by the spring.

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