Bakhyt Narikbayevich Absadykov

This study presents a preliminary analytical framework for evaluating the mass-geometric characteristics and rotating unbalance of a multi-station cam-screw mechanical press. The proposed configuration comprises two cam-screw actuators connected by a common working beam and incorporates a conceptual mechanically synchronised strip-feeding arrangement. The principal analytical contribution is a first-moment-based model for determining the centre of mass and static unbalance of an idealised asymmetric cam ridge represented by a constant-width polar volume. The model is supplemented by counterweight sizing, a numerical-geometric CAD comparison, dimensionless parametric sensitivity analysis, and an assessment of phase-dependent rotating forces and couple moments. For the nominal geometry, the calculated ridge volume is approximately 121.73 cm³, the radial centroid eccentricity is 37.41 mm, and the static unbalance is 35.75 kg·mm. The CAD-derived mass properties show small deviations from the analytical results, although both representations share the same geometric assumptions. The nominal working angular interval of 305° corresponds to an angular utilisation coefficient of 84.72%; however, this parameter does not establish an increase in production throughput. An additional fifth-order polynomial reference trajectory indicates that the maximum return acceleration for an illustrative 20 mm stroke increases from 123.68 to 343.55 m/s² between 300 and 500 rpm. The phase analysis demonstrates that cancellation of the resultant primary rotating force does not necessarily eliminate the associated couple moment. The results provide a basis for preliminary mass-property assessment and balancing calculations, while the actual cam–follower kinematics, complete rotor balance, structural response and industrial operating performance require further validation.

This study presents the analysis, design, and experimental–numerical evaluation of a double-chamber centrifugal-gyratory mill developed for the fine and ultrafine grinding of mineral raw materials. The operating principle is based on plane-parallel circular motion of two cylindrical grinding chambers generated by a crank mechanism. This motion produces an intensified centrifugal field and promotes simultaneous impact, compression, abrasion, and interparticle breakage within the grinding zone. An analytical model was developed to evaluate the influence of crank radius, rotational speed, chamber geometry, and grinding-body mass on the forces governing material destruction. At a crank radius of 15 mm and a rotational speed of 500 min⁻¹, the calculated centrifugal force acting on a 7 kg grinding body reached approximately 288 N, which is 4.2 times greater than its gravitational force. This confirms that the investigated grinding process is controlled predominantly by dynamically generated centrifugal loading rather than by gravity alone. Physical grinding tests demonstrated the ability of the mill to fracture hard mineral samples under intensive operating conditions, confirming the practical effectiveness of the combined impact–compression mechanism. Structural performance was assessed using global and local finite element models developed in Autodesk Fusion. The complete double-chamber assembly, subjected to three applied moments of 900 N·m, exhibited a maximum von Mises stress of 22.915 MPa, a maximum displacement of 0.050 mm, and a minimum safety factor of 9.033. The local shaft–chamber–support model, analysed under a torque of 500 N·m, produced a maximum stress of 65.837 MPa, a displacement of 0.740 mm, and a minimum safety factor of 3.144. In both numerical models, the maximum stresses remained substantially below the assigned steel yield strength of 207 MPa. The combined analytical, experimental, and numerical results demonstrate that the proposed mill generates sufficient dynamic loading for hard-rock breakage while maintaining adequate structural strength, stiffness, and operational safety under high-torque conditions.

This study presents the design and numerical evaluation of a mechanical cam-screw press with an optimized lower-drive configuration for high-quality steel product manufacturing. The proposed design relocates the drive mechanism from the upper part to the lower part of the press frame in order to reduce the structural height, lower the center of gravity, improve load transfer, and reduce deformation of the working zone. Analytical calculations were performed for a nominal pressing force of 630 kN, corresponding approximately to a 63 ton-force mechanical press. The static torque transmitted to the main shaft was 283.5 kNm, while the dynamic torque, calculated using a dynamic coefficient of 1.10, reached 311.85 kNm. Three-dimensional upper- and lower-drive configurations were developed in SOLIDWORKS Simulation 2024 (Dassault Systèmes SolidWorks Corp., Waltham, MA, USA), and finite element analysis was used to evaluate von Mises stress, total displacement, safety factor, and modal behavior. No-penetration contact was applied in the cam-screw and shaft-support regions, with a friction coefficient of 0.15 for lubricated steel-to-steel contact. The lower-drive configuration reduced the maximum static von Mises stress from 688.4 MPa to 642.7 MPa and the dynamic stress from 748.6 MPa to 701.5 MPa. The maximum static and dynamic displacements were reduced by 12.50% and 10.29%, respectively. Modal analysis showed that relocating the drive changes the dynamic characteristics of the structure; therefore, operating frequencies must be selected with sufficient separation from the natural frequencies. The results confirm that the optimized lower-drive configuration improves stiffness, reduces stress concentration, and provides a promising basis for compact and stable medium-capacity forming equipment. The limitations related to simplified contact modeling, belt-drive representation, thermo-mechanical effects, lubrication, and prototype validation are also discussed.

This paper presents a review and conceptual design justification of a mechanical press with a combined cam-screw actuator and a bottom-mounted drive. A comparative analysis of existing press equipment is conducted in order to identify the limitations of traditional crank, screw, toggle, and eccentric press designs. Based on this analysis, a conceptual layout of a cam-screw mechanical press with a lower drive arrangement is proposed as a promising direction for further engineering development. The paper discusses the possibility of using a cam profile to provide smoother tool approach to the workpiece and to reduce impact interaction during the initial stage of deformation. The proposed approach is considered at the conceptual level and forms the basis for further development of a detailed kinematic and dynamic model. Preliminary conceptual analysis indicates that a cam-screw press with a bottom-mounted drive may provide improved maintenance conditions, reduced impact loads, and better dynamic stability due to the lower location of the main drive components. The bottom-mounted drive is a strategic design solution that increases stability (vibration resistance), improves maintenance (drive units are within easy reach), and keeps the work area clean, as gearbox oil does not spill onto the workpiece. The proposed layout may contribute to reducing the overall press height and metal consumption; however, quantitative confirmation of these advantages requires further engineering calculations, numerical simulation, and experimental validation. The research results can be used in the design of next-generation high-precision cam-and-screw equipment, particularly for precision blanking, calibration, and micro-stamping equipment. Keywords: mechanical press, cam-screw mechanism, bottom drive, press design, kinematics, cam profile, dynamic stability, shock-free engagement.

In this article, an original method for the graph-analytical profiling of round-shaped form tools for external processing is proposed, distinguished by its ability to systematize and automate calculations. Unlike existing approaches, the new method allows for the calculation of the cutter profile with a frontal surface of circular shapes, using both graphical constructions and analytical formulas. The method is based on constructing three projections of the tool profile and calculating main and auxiliary geometric parameters such as angles ε and β, as well as linear parameters Aᵢ, Bᵢ, Cᵢ and radius Rᵢ. The graphical part of the method is presented as a 12-step procedure, which includes constructing the baseline, locating nodal points, and forming the form-cutting edge profile. The analytical part of the calculation includes seven steps detailing formulas for determining design distances, inclination angles, and tool radius. The proposed method ensures high accuracy and can be implemented manually or with software, especially when individual tool geometry is required. The methodology has been tested within the framework of a project on tooling support for the manufacturing sectors of the Republic of Kazakhstan and can be applied in the design and production of high-precision form tools. Keywords: form tool, graph-analytical calculation, external processing, tool geometry, profile radius, sharpening angles.

Introduction. This paper investigates the influence of deformation thermocyclic treatment (DCT) and subsequent normalizing on the mechanical properties and microstructure of low-carbon Steel 10. Low-carbon steels are widely used in engineering due to its high ductility; however, traditional heat treatment methods have a limited effect on its strength. Steel 10, with slightly increased carbon content, is more susceptible to heat treatment, which allows for optimizing the balance between strength and ductility. The purpose of the work is to determine the optimal parameters of DCT and normalizing for achieving the best combination of mechanical properties of sheet steel Steel 10. In this work, Steel 10 samples, produced by OJSC “NKMC”, were studied. The methods of investigation include the analysis of the chemical composition using an emission spectrometer ARL 4460. Samples were subjected to cyclic forging (DCT) on a hydraulic press, followed by rolling to a thickness of 3 mm. Mechanical properties (tensile strength, yield strength, elongation, and reduction of area) were determined using a testing machine Instron 3369. Results and Discussion. The results showed that DCT leads to grain refinement and texture reduction, which improves ductility. The optimal normalizing temperature is 900°C, providing the best combination of strength and ductility for both conventionally treated and DCT-treated steel. At the same time, DCT slightly increases the strength but significantly increases the elongation (by 15 %) and the reduction of area (by 11%). Subsequent normalizing of the DCT-steel significantly increases ductility (by more than 50 %) and reduces strength. The data obtained allow for optimizing the technological process to achieve the desired balance of properties.

This paper explores the possibilities and potential of 3D printing in the production of electric motor components, focusing on its transformative impact on prototyping, customization, and manufacturing. The main goal is to investigate the feasibility of producing functional and efficient electric motors using additive manufacturing technologies, particularly for Brushless DC (BLDC) motors. Key aspects include identifying which components can be effectively 3D printed and understanding the benefits and challenges of integrating 3D-printed parts into motor assemblies. The study examines successful examples of 3D-printed electric motors, such as Christoph Laimer’s 600W Halbach-array BLDC motor and others designed for drones, robotics, and educational purposes. These examples highlight the ability of 3D printing to create custom geometries, optimize material usage, and rapidly iterate designs. Furthermore, the research details ongoing efforts to print and assemble a Laimar-inspired 600W BLDC motor, emphasizing technical characteristics and the role of 3D printing in improving its efficiency and adaptability. By showcasing the potential applications of 3D-printed motors across fields like robotics, electric vehicles, and aerospace, the study concludes that additive manufacturing represents a groundbreaking shift in electric motor development. It not only accelerates prototyping processes but also reduces costs and opens new avenues for innovation in design and performance optimization. Keywords: Mechanical engineering, additive manufacturing, automotive industry, 3D printing, industry 4.0, drones, unmanned vehicles.

Additive technologies play an important role in modern automotive design and manufacturing, with their applications expanding every year. Originally used primarily for prototyping and mock-up production, 3D printing is now increasingly being used to manufacture key automotive components, with some companies offering fully 3D printed vehicles. This article analyzes the possibilities of printing load-bearing structures and the design of a key element - the electric motor mounting bracket for the TOQ car prototype. TOQ Prototype EV is an energy-efficient electric vehicle prototype being developed by the SU Racing Team from Satbayev University. The goal of the project is to create an ultra-light, durable, energy-efficient prototype vehicle with a long range of 1 kWh of energy. The use of new materials and additive technologies opens up the possibility of creating a variety of combinations, both for the production of parts with increased strength and for the use of advanced materials in the interior of the cabin. The process of prototyping an energy-efficient electric vehicle using additive manufacturing illustrates an innovative approach to improving energy efficiency and reducing energy consumption. This article details the process of designing an electric motor bracket using generative design and additive manufacturing. The study aims to evaluate the feasibility of 3D printing the load-bearing and critical elements of an electric vehicle prototype, as well as to simulate the loads when operating an electric motor with a peak power of 2 kW. Keywords: Mechanical engineering, automotive industry, additive manufacturing, 3D printing, industry 4.0, racing car, energy efficiency.

Additive manufacturing is of great importance in the design and manufacture of automobiles. The number of applications for 3D printing in manufacturing continues to expand on an annual basis. In the recent past, 3D printing was primarily utilized for the fabrication of prototypes. However, there has been a notable shift in the automotive manufacturing sector, with an increasing number of manufacturers adopting the technology for the production of significant automotive components. Additive manufacturing is employed to create design iterations, improve quality through cost-effective prototyping, and produce custom tooling parts. However, there are other areas of 3D-printing in the automotive industry that are more radically transforming products and supply chains. Additive technologies and the new materials used enable the creation of various combinations, both for producing parts with increased strength characteristics and for using soft materials in the interior of the cabin. Additive manufacturing aims to improve manufacturing processes and produce high-quality products in a short time. This article describes the main trends in the integration of 3D-printing technologies into the design and manufacturing processes of cars across various classes and companies. The main purpose of this article is to highlight the key aspects of additive manufacturing in the automotive industry. The use of these trends opens up new opportunities in the automotive industry of Kazakhstan.