The paper presents the results of numerical experimental studies of cutting titanium blanks using mathematical modeling programs, which make it possible to completely repeat technological processes in a computer (digital twin). The LS-DYNA product was used as a program to simulate the process of stock removal from titanium blank. It has been established that the use of this method adequately describes the cutting processes, including with the introduction of the energy of an ultrasonic field into the processing zone, can significantly reduce the duration of experimental research and evaluate the influence of the elements of the cutting mode and design parameters of the tool on the thermal power aspects of the formation of new surfaces of machine parts.

Basic methods to increase durability of die working parts including processes of cold plastic deformation at anti-wear coatings application by a method of ion-plasma sputtering are considered. A physical model of cold plastic deformation of samples made of heat-resistant steel H12M is presented.

A research technique was developed. The selection of the processed samples (sizes, material, operating conditions) was carried out. The physical and computational model of the process of cold plastic deformation of samples from tool heat-resistant steel X12M was developed. The technique for studying the effect of cold plastic deformation on the adhesive ability of a substrate – coating system is presented.

Polycrystalline composite materials made of carbon fiber reinforced plastics have more and more widespread application in mechanical engineering and become the main material for the production of modern types of high-speed transport. Thus, their share has already reached 35–45 % in the structural design of passenger aircrafts. However, the technology of machining surfaces of parts made of these materials, in particular, holes, is characterized by insufficient knowledge, the absence of regulatory standards for cutting modes and is most often based on the production experience of enterprises. When changing the processing conditions and the material, the pre-production engineering duration causes a significant increase in the cost of manufacturing parts due to the need for experimental selection of the cutting mode rational elements. To exclude the empirical selection of rational elements of the machining equipment cutting mode, the authors considered the possibility of using digital twins for studying the processes of drilling holes in the blanks made of composite materials, including those with the ultrasonic field energy introduction into the new surface shaping zone (to improve the processing quality and productivity). When modeling, the LS-DYNA program was used. The authors prepared the models and processed the results using the LS-PrePost 4.8 program. During the study, an explicit modeling method was used with preliminary validation and calibration of the results of tests of composites. The authors carried out calibration on test operations of tension, three-point bending, and interlaminar shear of the ВКУ-39 polymer composite material based on carbon fibers (carbon fiber reinforced plastic) widely used in domestic engineering. The developed finite element computer models allow simulating drilling procedures without carrying out rather complicated and expensive field tests. As a result of modeling, a simulation file was obtained, which reflects the process of drilling holes in a polymer composite material blank, as close as possible to the real-life situation with chip removal.

The paper considers the creation and research of a virtual prototype of titanium blanks drilling using the Lagrange and Galerkin method. The developed finite-element models are designed to study the process of mechanical treatment and optimize technological cutting parameters. The paper presents the results of computational investigation of titanium blanks drilling using mathematical modeling programs, which allow complete simulating operating procedures in a computer (digital twin). As a program to simulate the process of removing the allowance from a titanium workpiece, the authors used a multipurpose software product of finite-element modeling and analysis of highly-linear dynamic processes using various Ls-DYNA time integration schemes. The application of the Galerkin method allows adequately describing the drilling process with the introduction of the ultrasonic field energy into a treatment zone, can significantly reduce the duration of experimental research and evaluates the influence of the cutting mode elements and the tool design parameters on the power and energy aspects of the formation of new machine parts surfaces. Both methods are applicable to create various processes of mechanical treatment, however, the Lagrange method is less sensitive to the ultrasonic field energy. The introduction of the ultrasonic field energy into the drilling zone of workpieces made of hard-processing titanium alloys can significantly reduce energy costs. As a result of the simulation, the authors obtained a calculation file containing the simulation process, the solution of which visually reflects the drilling process of a titanium workpiece in a real-life setting with the removal of chips. However, for complete verification of numerical study results, it is necessary to carry out an experimental check and make adjustments to the calculated data.