What is the economic feasibility of manufacturing a metal-metal- polymer composite part compared to other technologies?

ABSTRACT

The purpose of the article is to analyse the manufacturing factors that affect the cost of manufacturing a part. Nowadays the cost of equipment used for metal 3D printing, as well as metal powders, are still very expensive. The cost of additive manufacturing of metal parts is mainly dependent on the volume of printing, therefore, reducing the volume of printing can lead to a significant reduction in the cost of manufacturing the part. Manufacturing of a metal shell, the cavity of which is filled with a cheap metal polymer, can be an excellent alternative to an all-metal part. The article provides a method for calculating the cost of manufacturing a lever part using various technologies: subtractive, additive, and composite part manufacturing technology. According to the calculated data, the dependence of the cost of manufacturing a part on piece time has been built, which can be interpreted as the amount of machining. The constructed linear dependence can give an idea of the effectiveness of the application of a particular technology for obtaining a part. In addition, non-economic factors affecting the possibility of using various technological processes for manufacturing a part are described.

KEYWORDS:

• Part
• technological time
• metal-polymer
• machining
• efficiency
• piece time
• mechanical engineering
• additive technologies
• composite
• prime cost

Data availability statement

The data presented in this study is available upon request from the respective author (Nickolai Lubimyi Email: [email protected]). The data are not publicly available as they are also part of ongoing research.

Acknowledgments

The authors acknowledge the services of LLC “Mashinostroitelny Zavod” in Belgorod.

Disclosure statement

No potential conflict of interest was reported by the author(s).

Additional information

Funding

This work was realized in the framework of the Program ‘Priority 2030’ on the base of the Belgorod State Technological University named after V.G. Shukhov. The work was realized using equipment of High Technology Center at BSTU named after V.G. Shukhov. The study was carried out at the expense of the scientific project No. ML-6/21 dated 11/22/21 on the topic: ‘Improving the efficiency of the process of obtaining parts of construction machines from composite materials through the use of topological shape optimization’; Program “Priority 2030” on the base of the Belgorod State Technological University named after V.G. ShukhovProgram “Priority 2030” on the base of the Belgorod State Technological University named after V.G. Shukhov [ML-6/21];

Notes on contributors

Nickolai Lubimyi

Nickolai Lubimyi In 2011 he graduated from the Belgorod State Technical University named after V.G. Shukhov with a major in mechanical engineering technology, and in 2018 he completed his dissertation and became the Candidate of Technical Science. From 2011 to 2011, he worked as a forging shop foreman at LLC ‘Belenergomash – BZEM’. Since 2018, he has been working as an assistant professor at the Department of Hoisting and Road Machines, BSTU named after V.G. Shukhov. The area of scientific interests of Lyubimy N.S. is the automation of manufacturing processes in various areas of mechanical engineering, the development of new and the improvement of existing technological processes for the manufacture of machine parts and the corresponding technological support. Special attention Lubimyi N.S. focuses on the practical application of the class of metal-polymer materials in the manufacture of functional composite products. The area of scientific research of Lubimyi N.S. connected with the study of the regularities of the influence of various technological factors on the process of manufacturing metal-polymer products and their properties. In 2017, he became a laureate of the ‘UMNIK’ grant from the Innovation Promotion Fund for the development of metal-metal-polymer moulding equipment for moulding thermoplastic polymers. In 2020, he was awarded a grant from the President of the Ministry of Education and Science of the Russian Federation. Today, he is in charge of a research laboratory for the additive production of composite parts with a topologically optimised shape.

Vladimir Pavlovich Voronenko

Vladimir Pavlovich Voronenko For the period of his work for five years, he headed the department ‘Technology of Mechanical Engineering’. Currently Voronenko V.P. is a member of the Dissertation Council D212.142 01, an expert of the Russian Accreditation Agency for the accreditation of universities and colleges and the Chamber of Commerce and Industry of Russia (he conducted an examination of Rosselmash and other commercial enterprises). He conducts an examination of grants through the Ministry of Education and Science of the Russian Federation, including under Government Decree No. 218 ‘On measures of state support for the development of cooperation between Russian higher educational institutions and organizations implementing complex projects to create high-tech production.’ Voronenko V.P. included in the register of experts of the Russian Academy of Sciences and has an expert certificate. Voronenko V.P. He is an Honorary Professor of Moscow State Technical University ‘Stankin’.

Andrey Polshin

Andrey Polshin In 2011 he graduated from BSTU named after V.G. Shukhov with a major in tool support for machine-building industries, and in 2021 he started postgraduate study. Andrey’s professional activity is connected with the manufacturing of metal-cutting tools and the study of cutting conditions of various materials, including composite ones.

Mihail Gerasimov

Mihail Gerasimov In 1972 he graduated from Belgorod State Technical University named after V.G. Shukhov with a major in Mechanical Equipment for Building Materials, Products and Structures. In 1972-1987 he worked at the Ferghana Polytechnic Institute as a teacher of special disciplines. In the same period, he completed postgraduate studies at the Moscow Civil Engineering Institute. In 1999 he defended his PhD thesis. Since 1996 he has been working at BSTU. Gerasimov’ s area of scientific interests is development, creation, testing, research and implementation of new models of the main technological equipment for technological manufacturing of the construction complex. Gerasimov M.D. has complete more than ten significant economic research works and grants in the field of moulding ceramic wall materials on belt presses, in the field of creating simulators for wheeled and tracked vehicles, in the field of theory and creating pilot samples of vibration devices with asymmetric vibrations. Gerasimov M.D. got patents for inventions and utility models. Gerasimov M.D. is the scientific director of the educational and research laboratory ‘Innovative vibration technologies and machines’. He is also the author of two monographs and a number of teaching aids and textbooks.

Antsiferov Sergey

Antsiferov Sergey In 2012 he graduated from BSTU named after V.G. Shukhov with a major in Mechanical equipment and technological complexes of enterprises of building materials, products and structures, and in 2017 he defended his thesis and became the Candidate of Technical Science. From 2013 to 2019 he worked as an engineer at the Department of Mechanical Equipment. Since 2018, he has been working as an assistant professor at the Department of Mechanical Equipment; since 2019, he has been working as a director of the engineering centre for digital design, additive technologies and PLM systems of the technopark of the Belgorod State Technical University named after. V.G. Shukhov. The area of scientific interests of Antsiferov S.I. is computer-aided design systems, modelling of technological processes, virtual reality, reverse engineering, additive technologies, generative design. Special attention Antsiferov S.I. focuses on digital design in the development of new products and the modernisation of existing ones. Antsiferov’s research area associates with the study of the use of additive technologies in construction and engineering. To date, Antsiferov S.I. manages the program ‘Priority 2030’ in the engineering centre.

Oğuz Kaan Öztürk

Oğuz Kaan Öztürk – In 2019, he graduated from Gazi University, Mechanical Engineering, Construction and Manufacturing Department. He met with additive manufacturing technologies during his university years and completed his first study in this field in 2019 with project on ‘Ultrasonic Additive Manufacturing Machine Design and Analysis’. After graduation, he worked with Prof. Dr. Oguzhan YILMAZ on WAAM applications within the body of Gazi University Mechanical Engineering Advanced Manufacturing Technologies Research Group (AMTRG). At the beginning of 2021, he started to work as Process-Parameter Development Specialist in Ermaksan-ENAVISION. At the same time, he is studying a master’s thesis on artificial intelligence applications in additive manufacturing under the supervision of Prof. Dr. Necmettin Kaya in the Department of Mechanical Engineering, Construction-Manufacturing at Uludağ University.

Boris Chetverikov

Boris Chetverikov In 2012 he graduated from BSTU named after V.G. Shukhov and received the qualification of ‘engineer’ in the speciality ‘Technology of mechanical engineering’, in 2016 he defended his thesis for the degree of candidate of technical sciences at MSTU ‘STANKIN’ in the speciality ‘Automation and control of technological processes and manufactures’. From 2014 to 2016, he worked as a design engineer in the generative design department of LLC ‘Standard Plastic Group’, which produces plastic products of complex shape and various technical directions. Since 2017, he has been working as an assistant professor at the Department of Hoisting and Road Machines, BSTU. V.G. Shukhov. Chetverikov’s area of scientific interests is the automation of technological processes, the creation of new methods and algorithms for controlling the geometric parameters of complex-profile parts. His field of scientific research is about the study of patterns that arise in the process of controlling deviations in the size and shape of surfaces of parts using control and measuring equipment, which is based on the principles of operation of non-contact measurements and vision devices. In 2020, he was awarded a grant from the President of the Ministry of Education and Science of the Russian Federation.

Alexander Tikhonov

Alexander Tikhonov In 2014, he graduated from the Kostroma Motor Transport College with a major in the repair and maintenance of motor transport. From 2014 to 2015 he served on conscription in the internal troops. In 2018 he graduated from BSTU named after V.G. Shukhov, specialising in ground transport and technological complexes. During the training, he actively participated in scientific conferences and he is the author of more than 60 scientific publications. Tikhonov’s area of scientific interests is the ground transport technological complexes and equipment. Tikhonov A.A. pays special attention on additive technologies in modern manufacturing. Tikhonov’s research area associates with the study of building mixtures for 3D printing, using anthropomorphic robots, and the expansion of technological capabilities. In 2020, he became the winner of the grant ‘UMNIK’ from the Innovation Promotion Fund for the development of tooling for the implementation and restaurant of small architectural forms with binders.

Vladislav Ryazantsev

Vladislav Ryazantsev In 2019 he graduated from BSTU. V.G. Shukhov, specialising in hoisting and road machines. In the same year, he started postgraduate study in the field of mechanical engineering. From March 2019 to November 2019, he worked as a mechanical engineer at Zeppelin Rusland, in the mining and quarry equipment division of CAT. At the Yakovlevsky GOK, he was engaged in the repair and maintenance of such equipment as lifting and hauling machines in the mines. In 2021, he won the grant ‘UMNIK’ on the topic ‘Rotor-vortex type reactor for ultrafine grinding’. His area of scientific interests in postgraduate studies concerns two research topics: Vortex layer devices for ultrafine grinding and disinfection of wastewater, and also, as for the topic of the dissertation, vibration devices with asymmetric vibrations in the construction industry. Currently, he is a 3rd year postgraduate student.

Shumyacher Vyacheslav Mikhailovich

Shumyacher Vyacheslav Mikhailovich One of the main areas of scientific activity of V.M. Shumyacher is research in the field of abrasives and grinding. On his initiative, since 1997, the annual international scientific-practical conference ‘Shlifabraziv’ has been held. Thanks to this, the direction of applied science, which is of great importance for industry, has been preserved in Russia. Scientific work of V.M. Shumyacher is also associated with the creation and processing of composite materials widely used in construction. Professor Shumyacher V. M. is the scientific supervisor of the scientific direction ‘Scientific foundations for the creation and operation of composites based on abrasive and superhard materials’ under the programmes of scientific research in the ‘Critical Technologies’ section of the Ministry of Education and Science of the Russian Federation.

Melentiev Nikita

Melentiev Nikita He is a student of the Transport and Technological Institute, Department of Hoisting and Road Machines, BSTU named after V.G. Shukhov. Since 2021, Melentiev is a research laboratory assistant at the research laboratory for additive manufacturing of composite parts with topologically optimised shape.