JPRS ID: 9243 USSR REPORT CONSTRUCTION AND EQUIPMENT

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• Content Type: REPORTS

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- JP~S L/9243 ~
,
7 August 1980 '
USSR Re ort -
p
CONSTRUCTION AND EQUIPMENT -
- (FOUO 8/80)
- ~
FBIS FflREIGN BROADCA~T INFORMATION SERVICE -
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' JPRS L/9243
7 August 1980
USSR REPORT -
CONSTRUCTION AND E~UIPMENT
(FOUO 8/so) -
~ CONTENTS PAGE
- CONSTRUCTION
Economic Effectiveness of Capital Investments
(M.. Ct~~entemirov; V~ROSY ERONOMII~I, Jun 80) . . . . . . . . . 1
METAIWORKING EQUIPMENT ~
Mjchines Outfitted With Numerically Progra~ed Control
(STANKI I INSTRIJMENT, May 80) . . . . . . . . . . . . . . . . . . . 14
Results, Future Progress -
Monitoring Devices, by t. A. Batalin, et al.
New Line of Milling Machines, by N. I. Ivanov,
e t al.
- ~
- a - [IZI - USSR - 36a FOUO]
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CONSTRUCTION
ECONOMIC EFFECTIVENESS OF CAPITAL INVESTMENTS
_ Moscow VOPROSY EKONOMIKI in Russian No 6, Jun 80 pp 34-43
/Article by M. Chentemirov: "Ways of Increasing the Economic Effectiveness
of Capital Investments"/
/Text/ Construction in our countzy has become a most important sector of
the national economy. It has a decisive influence on the development and
distribution of productive forces, the increase of the production potential -
of the ~ountry and the assurance of a steady increase of the standard of
living of the pe~ple.
In the past 25 year the volume of construction in the USSR has increased
more than eightfold. In the amount of capital investments the USSR holds
first place in the world, having exceeded the level of the United States,
as well as of the FRG, England, France and Italy taken together. During
the years of the Eighth Five-Year P1an the total amount of capital invest-
ments was 347.9 billion rubles, the Ninzh Five-Year Plan--493 billion
rubles, for the lOth Five-Year Plan it is envisaged in the amount of
621 billion rubles. -
The increase of the amounts of construction has entoile:i a change in ~.ts
- structure and territorial distribution. The proportion of capital ir.,~Jest-
ments in the eastern regions has reached nearly 20 percent. 'T'he value of
the equipment for production facilities increased to 46 percent. In all _
68 percent of the capital investments in productior. construction are spent
for the expansion, renovation and retooling of operating enterprises.
A material and technical base of construction has been created in the coun-
try and is cons*_antly being strengthened. In constructiAn and at construc-
tion industry enterprises there are about 160,000 excavators, more than
43,000 ~crapers, over 161,000 bulldozers, nearly 200,000 traveling cranes, `
more than 1.15 million trucks and special vehicles and other construction
and transportation equipment.
:iowever, the achievements of capital construction could have been more ap-
preciable. During the past years of the lOth Five-Year Plan it has not beeii
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possible to achieve an appreciable improvement in capital construction.
L. I. Brezhnev at the November (1979) CPSU Central Committee Plenum indi- -
cated that "the construction periods are often prolonge.d. The unfinished
construction has considerably exceeded the standards. Often resources are
allocated for far from priority construction projects. Not only errors and -
- regionalism, but also cases of abvious arbitrariness are occurring here."
A significant amount of inetal products is not being delivered to construc-
tion organizations. In 1979 four construction ministries alone (the USSR
Ministry of Construction of iieavy Industry Enterprises, the USSR Ministry
of Industrial Construction, the USSR Minisrry of Construction and the USSR
Mi.nistry of Installation and Special Construction Work) wcre not supplied
with 728,000 tons of rolled ferrous metal products (7.5 percent of the an-
nual budget), including 586,000 tons of rolled products made fram low-alloy
steels, or 15.7 percent. Cdnstruction projects are also being unsatisfac-
torily s~ipplied with cement, lumber, asphalt, limoleum and a number of
= other critical materials. ~
The imbalance is manifested first of all in the inadequate coordination of
_ the plan assignments with the capacities of construction organization~.
The practice of the uneven distribution in the plan of the assignments on -
- placing production capacities and fixed capital into operation by quartars -
of the year has not yet been eliminated. About 75 percent of the annual
program of the placement of fixed capital into operation is planned for the
~ second half of the year. This shortcoming has also not been eliminated in
the plan for 1980.
This upsets the smoothness of the work of contracting organizations, leads
to the nonfulfillment of the assigizments on the placement of facilities
into operation and is conducive to the appe3ra~zce oi large amounts of un-
finished construction.
The number of new construction projects, which are included simultaneously -
in the plan~ continues to remain enormous. For example, in the 1979 plan
the number of production construction projects alone came to nearly 41,000,
- of them the newly begun construction projects cnnstitute a significant share
" (more than 10,000). Moreover, in excess of 37,U00 more enterprises, for
which the construction or renovation of facilities is envisaged, are in-
cluded annually in the plan. In this case more than 35 percent are newly
: begun co~.istruction projects. -
Thus, approximately 78,000 production constructian projects, including
30 percent which are being newly begun, are at t`!e stage of construction or
renovatian (expansian).
_ ~
� As a result due to the inclusion in the plar,~ of such a number of newly be-
gun construction projects r~ot enough capital investments for start-up con-
_ struction projects at the same t.ime ~sre not being provided. For example, -
in 1979 they failed to receive in ex~:.ess of 2.5 billion rubles. The
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construction period~ arz being prolonged, the standards of duration are not
- being observed and the national economy is not receiving that impact in the
form of additional produ~ts, which is stipnlated in the plans for the con-
struction of enterprises. -
, In 1979 of the total number of new construction projects 24.4 percent were
construction projects, for which the standards of the duration of construc-
tion had been surpassed. In order to complete them nearly 4.5 years will
be additionally required. The proportion of new construction projects with
elapsed standard terms o f the duration of construction is even more signifi-
cant in the USSR Ministry of the Gas Industry (42.8 percent), the USSR Min-
istry of the Chemical Industry (42.6 percent), the USSR Ministry of the
Atuomotive Industry (38 percent), the USSR Minist:y of the Petroleum Ref in-
ing and Petrochemical Industry and the USSR Ministry of Ferrous Metallurgy
(31 percent), for the completion of which from 2.5 years in the Ministry of
the Gas Industry to 13.5 years in the Ministry of the Automotive Industry
will be additionally required on the condition that henceforth the capital
investments will be allo cated at the leve!. of preceding year~.
- For a number of years the level of unfinished construction has remained
high and from year to year has increased, reaching in 1979 91 percent of
- the amount of state cap i tal investments, or 104 billion rubles. The excess
of the standard level was 24 points, or 27.3 billion rubles. At the same
time it should be .zoted that during different periods of time the flucCua-
tions of the amount of unfinished construction have been very significant.
Thus, starting in 1957 a cendency toward a steady decrease of i:he 7_evel of -
unfini~hed construction was n~ted, and by 1964 it was 16 points. Since
= 1965 the level of unfinished construction has increased from ~~ear to year,
having reached at this t ime amounts which are almost equal to the annual
_ amount of capital inves tments. The amount of unfinished design a*?d survey- -
ing work is also si~nificant. At the beginning of 1979 it was equal to
nearly 9 billion rubles.
As a result of the prolonging of the per~ads of designing and construction -
the obsolescence of planning documents ~s o~::urring, therefore in excess of
- 18 percent of them are liable to being written off and about 13 percent are -
liable to thorough revi s ion.
The increase of unfinished construction and the unsatisfactory fulfillment
of the assignments of the state plan attest that mi~zistries and departments
are devoting inadequate attention to questions of capital construction and
especially to such an advanced direction of capital in~;estments as the _
renovation and retooling of operating enterprises. In the plan for 1g79
their proportion was less than one-fifth of the amount of the capiCal in-
vestments in production facilities.
, The work on the draft of the plan of capital construction for 1980 was car-
ried out on the basis of the observance of the principles and provisions of
the decree of the CPSU Central Committee and the USSR Council of Ministers
of 12 July 1979. Attent ion was first of all devoted to the assurance of
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= the concentration of capital investments at start-up and carryover construc-
tion projects, the acceleration of the placement of production capacities ,
and facilities into operation, as well as the actcievem2nt of a balance be-
tween the outlined amounts of work and the material and technical resources. _
As a result it was possible to reduce the number of newly started construc-
tion projects with an estimated cost of up to 3 million rubles, the title
sheets for which are subject to the approval of the USSR Council of Minis-
- ters. Thus, instead of 652 such construction projects 356 were included in
the plan.
USSR mi.nistries and departments and the council5 of ministers of the union _
republics have also been order~d to reduce the number of newly started con-
struction projects with an est:imated cost of up to 3 million rubles.
At present the country has an enormous production and technical potential.
At the beginning of 1979 the fixed capital was 1.54 trillion rubles, of
them 1,006,000,000,000, or 65.3 pe~cent, are for production purposes. The
fi:~ed production capital of the national economy during 1971-1978 incrc~ased
_ 189.5 percent, in industry by 187.9 percent. _
- But in recent years a decline of the output-capital ratio has been observed
both for the national economy as a whole and for industry. Such a situation
is unquestionably connected with the increase of the capital-output ratio
of the products being produced, which has been caused by the increase of the
demands on the technical level, the mechanization and automation of produc-
tion, by the increase of product quality, the improvement of the working con-
ditions of the workers and the implementation of environmental protection _
measures. At the same time there are also serious shortcomings in *_he use
of fixed productioz capital. The slow assimilation of the rated capacities
aC the enterprises put into operation and the unsatisfactory use of the
available production capacities adversely affected the amount of the output- -
capital ratio. ~ ~
One of the ~ost impo~tant questions in construction is the provision of _
construction projects with a regular labor force. In connection with the
considerable decrease of the number of young people, who are reaching able-
- bodied age, the balance of manpower resources has been upset some~hat,
which has lead to the inadequate provision of construction with manpower.
' In 1979 the supply of a regular labor force was 98 percent of the planned
supply.
The losses of working time are still great oc~ring to shortcomi.ngs in the
organization of construction work and the provision of constructi~n ~rith
material and technical resources. According to the data of sample surveys,
which have been conducted by standards research stations, in 1979 the inter-
shift losses of working time on the average were 8.5 percent of the worked
time for construction, 12.1 percent at the organizations of the USSR Minis-
try of Construction of Petroleum and Gas Industry Enterprises, 10.6 percent
at organizations of the USSR Ministry of Rural Construction and 10.1 per-
cent at organizations of the USSR Ministry of Power and Electrification.
-4.
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'I'he reduction of nonproductive labor inputs (hidden losses of working
time), which in 1979 were equal on the average to 7.5 percent of the shift
~ time, and in some ministries were even higher: 13 percent in the USSR Minis-
try of Rural Construction, 8.8 percent in the USSR Ministry of Construction,
is a serious reserve of the economy of working time. These losses form
mainly due to the violation of the technology of operations, the low qual-
ity of the components and materials delivered to construction projects,
shortcomings in their storage and so on.
The extensive dissemination of the brigade contract method is one of the
- effective means of improving the use of the regular labor force in construc-
tion. In the first half of 1979 more than 70,000 brigades numbering nearly -
900,000 workers worked according to this method. They performed 32.5 per-
cent of the total amount of construction and installation work, while dur-
ing the corresponding period last year they performed 28.1 percent of it.
The brigades, which have been c~nverted to the contract, exceeded the six-
� month assignment on the increase of labor productivity by 7.3 percent, re-
duced tne planned cost of the work by 3,6 percent and provided an economy
of assets in the amount of 249 million rubles. At the same time the effi-
ciency of cost accounting brigades would have been higher, had they worked
- according to this methad continuously for the entire year. Analysis shows
that the brigades work on the contract only 60 percent of the working time.
This happens mainly due to the inadequate preparation of production, and in
_ a number of cases the underestimation by some economic managers of this ad-
vanced method.
In recent years the proportion of skilled workers employed in construction
has increase3. The need of construction.for them is being met by on-the-
job training (54.4 percent), the recruitment of graduates of vocational and
technical scheols (18 percent) and the hiring of skilled workers by con-
struction organizations locally (27.6 percent). _
However, the plans of the admission of young people and the training of
- young workers in the system of vocational and technical education are not
being fulfilled. At many vocational and technical schools of construction
specialization, as in previous years, the training of workers of noncon-
;.,truction occupations is continuing. The assignments on assigning skilled
workers to construction are also not being fulfilled.
As a result the proportion of wor':ers, who have graduated from a vocational
and technical school, in the total number of workers engaged in construc-
tion and installation work and at auxiliary works in the past 10 years has
decreased from 6 percent to 3.8 percent.
~ Demographic changes and the difficulties connected with them in providing
construction in the next few years with a regular labor force require the _
considerable improvement of the work of construction ministries and depart-
ments and the system of vocational and technical education as a whole on
_ the training of construction workers and the improvement of their use.
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Scientific and technical progress in the nationa? economy is making quali-
tative changes in the technical level of capiral construction. The amounts �
and complexity of the construction and installation work of the industrial
complexes and facilities under construction are increasing significantly.
The unit capacities of the enterprises being built and their technical
equipment are steadily growing. For example, in the chemical industry the
capacities for the production of ammflnia increased from 200,000 tons a year
to 450,000 tons, sulfuric acid--from 180,000 tons a year to 500,OOt~ tons;
in ferrous metallur~3' the unit volume of blast furnaces increased from
2,000 m3 to 5,500 m~; in the petrochemical industry the capacities of
petroleum refining blocks increased from 2 million tons a year to 8 million
_ tons.
The 3.ncrease of the organizational and technical level of cot:struction to a -
large extent depends on the quality of the drafting of the plans of the
organization of construc~ion (POS's) and the plans of the performance of
operations (PPR's), which call for a shift to a new, higher level of produc-
tion control and ensure tl:~ timely placement of capacities an3 facilities
into operation, the fulfillment of the assignments on the increase of labor
productivity and the considerable increase of the effectiveness and quality
of construction.
In recent yea.rs some design institutes of Moscow, the Ukraine and the Urals h~~~e
gained experience in the drafting of organizational and technological docu-
ments. The designers iointly with the builders are ensuring the high qua.l-
ity and timely preparation of *_he plans of the organizati.on and the plans
of the per~ormance of operations for t_Ze construction of industrial com-
plexes and facilities. The work of the Dnepr River region Main Administra-
tion for Construction and Planning of Industrial Enterprises of th4 USSP.
State Committee for Construction Affairs and of the construction organiza-
tions of the Ukrainian SSR Min~stry of Construction of Heavy Industry Enter-
- prises on ferrous metallurgy projects and the preparation by the All-Union `
Scientific Research Institute of Planning of Hydroprojects imei.i S. Ya. _
Zhuk of the USSR Ministry of Power and Electrification of the organization-
al and technological documentation for the construction o� the Kama Motor ~
Vehicle Plant are positive examples in this area. However, there are few _
such examples. Moreover, the review of the plans of industrial enterprises _
and facilities by the Main Administration of State Experts ~f the USSR State _
Committee for Construction Affairs shows that the quality of the draftir~
of the plans of the organization of construction has decreased in recent
years.
The increase of the technical level of construction largely depends on the -
methods of performing the operations, the organization of construction work,
_ the provision with means of small-scale mechanization and standard sets of
equipment, as well as the instruction of workers in advanced labor metr~ods.
The design and technological institutes and Orgtekhstroy trusts are tak-
ing an active part in solving these complex pr:~blems. They are als~.~ giving
practical assistance to construction and ins*_allation organizations and
enterprises of the construction industry in the introduction of new
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equipment and advanced technology and in the drafting of plans of the per-
formance of operations.
In recent times construction and installation organizations and many Org-
tekhstroy trusts have begun an intensive search for new, improved forms and
methods of the organization of construction work. Much attention is being
devoted to questions of the engineering and technological pregaration of
production. Such effective organizational methods as the block method of
the designing, preparation, organization and management of the construction
of complicated facilities and major industrial complexes have appeared. -
_ The essenc~ of the block method consists in the fact that the structurally
and technologically dependent parts (b~ocks) are singled out within the
start-up ~omplex for the purpose of organizing a technologically sound
amount of work and achieving in the shortest possible time the technical
readiness, which is necessary for the independent testing and adjustment
of individual production lines, deparCments and plants. The block method _
was elaborated and introduced for the first time at construction projects `
of the Ukraine, where there were built using it: the ~.omplex oi the oxygen -
_ converter shop and the 3600 mills of. the Azovstal' Plant, blast furnace
No 9 of the Krivorozhstal' Plant, the Khartsyzsk Pipe Plant, the complexes
for the production of ammonia at the Severodonetsk Azot Productior~ Associa-
tion, the Odessa Port Plant and other facilities. In all in 1978 35 proj-
ects and complexes were built according to this method. At most of them
the period for the placement of the capacities into operation was shortened
by up to six months and a substantial economic impact was obtained. Accord-
ing to the data of ministries and departments, during the llth Five-Year
Plan they are proposing to carry out the adoption of the block method at -
more than 100 complicated projects and major industrial complexes.
The effectiveness of this method is explained by the rational concentration
and use of material, technical and manpower resources within the complex, .
the possibility of combining the operations for the complex by means of the
organization of parallel flows, the precise coordination of operations w;~th-
in each block and for the complex as a whole, the development of a reliable ~
_ automated system for the planning of the performance of construction and -
installation work and resources, for operations management and production
control of the progress of construction. -
The allocation of considerable capital investments for the developmant of
the natural resources of the Far North and remote regions of the country is -
envisaged during the lOth Five-Year Plan and in suhsequent years. In these
regions it is expedient to carry out the performance ~f construction and
installation work by the forces of mobile formations, which have been sta-
_ tioned in inhabited regions, with the regular travel of the shift workers
to the construction projects (the special field effort method of construc-
tion). This method of construction in recent times has been used extensive-
lq in the development of oil and gas fields, the construction of petroleum
and gas pipelines, compressor and petroleum-pumping stations, gas treatment
plants, geological prospecting and lumbering operations.
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At present the USSR State Com~ittee for Construction Affairs jointly with
the Ministry of Construction of Petroleum and Gas Industry Enterprises is
= performing work on the study and generalization of the gained experience of
using the special field effort method of construction of facilities of the
- petroleum and gas industry for the purpose of preparing the appropriate
recommendations on its further improvement and extension to other sectors
of industry. According to the data of the Ministry of Construction of
Petroleum and Gas Industry Enterprises, the use of this method of organiz-
- ing labor in the regions of the North, Siberia and the Far East will make
it possible to reduce sharply residential housing construction, which is
expensive in these regions.
Complex goal programs of advanced organizational and technical solutions
are being introduced at many leading construction projects with the partici-
pation of scientific research organizations c,f the USSR State Co~ittee for
Construction Affairs and Orgtekhstroy trusts. The long-term Promkompleks
program at the construction site of the U1'yanovsk Industrial Center and
the long-term Oskol program at the construction site of the electrometal-
lurgical combine are most significant in this respect. They are making it
possible to increase labor productivity by 8-10 percent, to shorten the
duration of construction by up to 10 percent, to improve the quality and
in this connection to reduce subsequently the expenditures on the operation
of buildings and equipment. The anticipated economic impact from the intro-
duction of such complex programs should be 1.5-2 percent of the cost of the
construction and installation work.
� Such local goal programs of the introduction of effective technological
processes for specific types of operations as the Termobeton, Pnevmobeton
- and Monolit programs, which were drafted and recommended by institutes of
the USSR State Committee for Construction Affairs, are of great interest. -
The Termobeton program, for example, contains recommendations on the erec-
tion ~f various ~onolithic components in winter with the use of a thermoset-
- ting concrete form and systems of automatic temperature control equipment.
- The economic impact in the erection of concrete and reinforced concrete
components will be (according to preliminary data) about 5 rubles per cubic
meter of poured concrete.
In conformity with the Progress program by means of the extensive use of
"dry blocks" and items made from plaster it is planned to increase consider-
ably the output of decorators. For this the additional output of improved
dry plaster, plaster panels, blocks produced by the extrusion method and so
on is planned at construction industry and construction materials enter-
prises. The construction ministries are also implementing other long-term
goal programs, which are aimed at increasing the organizational and techni- -
cal level of construction.
- In recent times large-block methods of the erection of buildings and struc-
tures, the preliminary assembly and consolidation of equipment, the combin-
ing of installation and special construction operations, mechanized and
automated methods of welding have been used extensively. -
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The method of large-block installation of equipment weighing in excess of
250 tons using vertical boom and crane equipment, as well as hydraulic
hoists has been further developed. For example, the insi;allation of pro-
pylene columns weighing 500 tons was carried out at the l3uder_ovsk Plastics =
Plant, a hydraulic press with an operating force of 15,OU0 tons and units -
w~ighing up to 500 tons--at the Volgodonsk Ato~nash Plant:, a reaction ves- _
sel weighing 730 tons--at the Omsknefteorgsintez Production Association.
The methods of the p reliminary assembly and subsequent sliding of units ~
into the planned position are used widely. Thus, the preliminary assembly
with the subsequently sliding of the unit of the gas scrubber weighing -
_ 620 tons was carried out at the Bakal Ore Preparation Combine, a head im-
pact machi.ne weighi.ng 6,000 tons--at the Soligorsk Potassium Combine, the
block of blast furnace No 1 weighing 14,000 tons--at the Western Siberian _
= Metallurgical Plant. In 1979 alone with the installation of 885,000 tons _
of technological equipment in large blocks the USSR ~Iinistry of Installa-
tion and Special C~nstruction Work reduced the labor inputs by 480 men a
year and obtained a saving in the amount of 80.5 million rubles.
The movement for the creation of model construction projects is of great
importance. The USSR State Committee for Construction Affairs, the Central
Committee of the trade union and the Scientific and Technical Society of
the Construction Industry have announced the All-Union Inspection and Com-
- petition for the Best Organization and High Standard of Construction Work.
The goal of the competition, which will be held annually (with the tallying
of the results by the Day of the Construction Worker), is the improvement
of the organization of construction work, the increase of its standards,
the observance of technological discipline at construction projects, the
increase of labor productivity and other technical and economic indicators.
Measures on the further mechanization and automation of construction work
have to be implemented and the structure of the fleet of construction
machinery has to be improved considerably. In the next five years it is
necessary to increase the average unit capacity of the machinery in the
fleet by 25-30 percent. In particular, it is planned to increase the capac-
- ity of the scoop of excavators from 0.51 m3 in 1978 to 0.~9 m3 in 1985, the
power of bulldozers respectively from 93.2 hp to 125 hp; the lifting capac-
ity of crawler-mounted cranes--from 26.7 to 36.5 tons, the carrying capac- -
ity of trucks- from 6 to 7 tons. All this will make it possible to reduce -
significantly the number of vehicle and motor transport service personnel, _
whose number at present is more than 2 million. _
One of the most important tasks of the improvement and increase of the ef-
fectiveness of construction is the increase of the results of scientific -
research and the quickest possible introduction of scientific and technical
achievements in practice. In order to ensure further progress in construc-
tion it is necessary first of all to continue the work on the reduction of
= the weight of buildings and structures, the consolidation of components and
items, the increase of the plant readiness, the elaboration of more effi-
cient design solutions with the use of new materials and �irst of all
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- efficient heaters, the increase of the level of inechanization and the im-
= provement of the organization and technology of construction. This will -
create the conditions for the further increase of labor productivity and
the reduction of the cost, materials-output ratio and labor-output ratio of
- construction. What is meant is that during the forthcoming five years an
= increase of the proportion of construction and installation work, which is
performed using the achievements of science, technology and advanced know- _
how, by not less than 60 percent and of the production of new products in
� the construction components and materials industry by approximately 65 per-
cent should be ensured.
Such an increase can be ensured only on the condition of the purposeful im-
prov~ment of design decisions, fo.r which it will be necessary to elaborate
and introduce a new system of the evaluation of the technical level of de-
sign decisions and first of all according to such indicators as the labor-
- output ratio, the materials-output ratio, the proporticn of the operations
which call for the use of new equipment and so on.
In the construction industry the amount of construction of industrial enter-
- prises within industrial centers with common facilities of the auxiliary -
works and managements (power, transport, repair and so forth), engineering
structures and pipelines has to be increased, having ensured an increase of
- the proportion of this construction from 10 to 30 percent. This will make
it possible to reduce the capital investments by 3-4 percent, the area of
the construction i~z progress by 8-LO percent and the length of the roads
and railroads by 15-20 percent.
In the designing of auxiliary production facilities (pumping, compressor,
_ boiler and oxygen stations, maintenance s*ations of electric loaders and
so on), industrial and agricultural enterprises, their interconnection with
each other and with the main buildings, as a rule, will be stipulated,
- which will make it possible to save up to 50 million rubles a year, to re- -
duce the grounds of enterprises and to shorten the pipelines and roads.
- The construction of two-story buildings with technical lower floors for the -
location of warehouses, ventilation equipment, pipelines and so forth,
especially for enterprises of those sections, in which production facilities
with specific temperature and humidity conditi~ns and the servicing of ~
pipelines outside the production facilities are needed, will be expanded.
The cost of construction will thereby be reduced by 10-15 percent and the
adjusted expenditures by 20-30 percent, the area of the construction in
. progress will be decreased by 40-50 percent.
It is necessary to use mor~ extensively in the planc the outdoor location of
technological equipment, which makes it possible to reduce the cost of con-
- struction by 10-25 pexcent, to decrease the a.rea of the construction in
progress by 10-15 percent and to increase the explosion proofness of pro-
duction. -
~ In the designing of industrial facilities and in the production of construc- -
tion components and technological equipment provision is made for the _
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extensive use of large light-weight blocks, including construction and tech-
nological blocks, which consist of large installation units of supporting
and enclosing construction components in combination with elemEnts of the
_ engineering and technological equipment, which reduces the labor inputs in
installation to one-third to one-half; blocks of standard-unit technological -
equipment, first of all in the construction of projects of the petrochemi-
- cal, chemical, food and medical industries, main petroleum and gas pipe-
lines and water management projects, which shorten by 15-20 percent the -
period of construction of the projects and reduce by 10-15 percent the con-
sumption of inetal by the shortening of pipelines; blocks of the heat engi-
neering equipment of boiler houses, which will make it possib?e to save an-
nually up to 30 million rubles and to release more than 15,000 people who
are engaged in installation.
In agricultural construction it is expedieni; to standardize and thereby to
reduce the list of standard plans of production facilities. To use, as a _
rule, light-weight reinforced concrete, reinforced cement, asbestos cement,
wood, metal, polymer and other components and items of a high degree of ~
plant readiness. Production, delivery in complete sets and installation -
~ should be carried out by the forces of rural construction combines. This
will make it possible to reduce sharply the duration of construction, the
cost of construction per unit of production by 3-S perce.nt, the labor-
output ratio by 12-15 percent, the consumption of materials by 10-12 per-
cent, to improve the working conditions of the construction workers and to _
increase the durability of the buildings by 1.5-fold to 2-fold. The pra-
- portion of the construction of completely prefabricated buildings needs to
be increased to 55 percent. Effective reinforced concrete components, as -
well as glass concrete components, which ensure a considerable reduction
of the materials and labor inputs during their preparation and installation,
should also be used extensively.
The plant production of wood panel houses and sets of wood parts for houses
orith walls made from local materials for rural housing construction has to
be expanded and it has to be increased in 1985 to 8.55 million m2 of total
area. Here the houses should be supplied with engineering equipment with
the necessary fasteners and accessories, as well as wood items for the
out buildings.
In water management and reclamation construction it is envisaged to increase
the use of polyethylene pipe in the ascending pipelines of irrigation and
water supply, which makes it possible to inc�rease the speed and quality of -
construction, the durability of the pipelines; to use extensively the
ditchless methods of laying polyethylene, as well as steel pipe when con-
structing covered drainage and pressure irrigation systems, ditchless drain
layers which are equipped with laser systems, and thereby to increase, for _
example, the speed of the laying of drains ma.de from polyethylene pipe by
two- to threefold, to obtain a saving of up to 20,000 rubles a year per set -
- of drain layers; to increase considerably the proportion of covered drains '
and plastic pipe, which are laid by the ditchless method, in the total _
amount of construction of the covered drainage system.
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As a rule, monoblock deep-well electric pumps will be used in the construc-
tion of pressure irrigation systems, which makes it possible to eliminate
thF construction of buildings of the pumping stations. The proportion of
irr~gation pipelines made from precast reinforced concrete pipe in the to-
tal amount of construction of irrigation pipelines will increase 1.5-fold.
In state and cooperative residential hou~ing construction the proportion of
large-panel and modular house building will be increased. According to
estimates, by 1985 it is possible to increase its proportion to 60 percent.
The changeover to the construction of large-panel apartment houses accord-
ing to new standard plans with an improved layout and greater comfort will _
be expedited. The proportion of construction of prefabricated cultural and _
general buildings will amount to 33 percent.
Here it is necessary to carry out the work on the equipment and finishing _
of facilities, as a rule, by "dry methods," in the form of the installation
of body-shell and sliding partitions, prefabricated blocks of bathrooms,
built-in furniture, while it is necessary to perform the facing of walls -
with large plasterboard, fiber-plaster, plastic and slag-devitrified glass
_ sheets, covering with polymer films with an adhesire layer, the laying of
floors with linoleum on a heat insulating and soundproofing base the dimen-
sions of the room, parquet boards and sheets, synthetic carpets, which will
make it possible to reduce the period of the operations, decrease their _
labor-output ratio by 15-20 percent and considerably improve the quality.
Advanced economical pile and slab foundations and thin-wall subsurface -
structures will be used more extensiveiy in the designing and construction
of buildings and structures. Among them are foundations tna.de from rein- _
forced concrete driven and tamped piles in the form of light large slabs; -
subsurface structures with thin reinforced concrete walls, which are built
by the "wall in the ground" method, and the sinking of the shafts in thixo- -
tropic casings; foundations and buried facilities with the use of ground
anchors.
Large, light, thin-wall components made from high-strength heavy, light and
- foam concretes and brick; driven piles without the cross reinforcement of
the shank, columns of one-� and two-story buildings made from high-strength
concretes, of effective cross sections for several stories with efficient _
butt joints; multihollow roof panels with light reinforcement; floors in
imitation of steel shaped planking; modules of rooms, kitchens, bathrooms,
elevator shafts and stairways; panel partitions; panels of roll-less and
bare roofs; three-ply wall panels and so on should be used more extensive-
ly in construction.
The problems of the designing and production of steel components and items
and their use in construction are acquiring a special significance under
- present conditions. There will become more widespread columns, trusses and
beams of roofs made from wide-flange Ii- and `r-bars, bent-welded sections
_ and single angles, the use of which will make it possible to reduce the cost
of 1 million m2 of roofing by 2-3 million rubles, the labor-output ratio by
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20-25 man-years, the consumption of steel by 4,000-6,000 tons; structural
components of roofs made from rolled sections, the cost and labor-output
ratio of the production and installation of which are substa:ztially lower
than simi.lar components now being used; two- and three-ply panels of walls
and ceilings; window and skylight frames madP from thin-wall tubular and -
' bent steel sections in combination with openers, which will make it pos-
� sible to save annualy more than 100,000 tons of steel; large, acoustically
- highly effective panels of suspended soundproof ceilings.
The considerable increase of the amounts of construction require a higher
rate of development of the industry of construction components and parts,
as well as the improvement of the use of the production capacities of
operating enterprises and first of all large-panel and modular house build-
ing. The overcoming of narrvw departmental trends in this area, which are
leading to the underutilization of the production capacities of operating
enterprises, the increase of the need of capital investments for the crea-
tion of new enterprises and managements of the material and technical base
of construction, the appearance of small, poorly mechanized warks, ultra
long-range shipments of components and materials and so on, is an important
task. The increase of the technical level of production should ensure the
improvement of product quality and a considerable increase of the degree of
plant readiness of components and items.
One of the primary tasks of the construction materials industry is the
meeting of the need of construction for new, advanced construction mate-
rials, including high quality, extra fast setting, stressing and colored
- cements, meltable roofing material, linoleum on a heat insulating and
soundproofing base and carpeting for floors, backing films, large facing
sheets made from plastics, plastic pipe and strapping items, sealers,
- plasterboard and fiber-plaster sheets, double glass panes, facing sheets
made from slag-devitrified glass and other effective materials. It is nec-
essary to develop more extensively the production of brick wall panels and
blocks, local binders, alkaline slag binders with the use of industrial
- wastes and nonmetallic construction materials.
The achievements of construction also depend on a number of other sectors
of industry and first of all metallurgy, the chemical industry and machine
building. Meanwhile the sector is being inadequately supplied with rolled
products made from ste~ls of higher and high strength, stainless steels,
paints and varnishes for protecting construction components against corro-
sion, superplasticizers for concrete mixes, synthetic resins, fiberglass
materials, new highly productive equipment for driving tunnels, drilling
~ holes in permafrost grounds for the piers of bridges, special motor trans-
port, hydraulic dredges, underwater graders, floating cranes and so on.
- The necessary conditions for the sharp increase of the technical level of
construction, the growth of labor productivity and the improvement o~ the
- quality of the construction product can be created only as a result of th~
pooling of the efforts of the construction and industrial ministries and
departments.
COPYRIGHT: Izdatel'stvo "Pravda", "Voprosy ekonomiki", 1980
7807
CSO: 1821 13
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f�1ETALWORKING EQUIPMENT
1~1ACHINES OUTFITTED WITH NUMERICALLY PROGRAMMED CONTROL
Resu]ts,Future Progress
1~loscow ~TANKI I IN;TRUMENT in Russian No S,May 80 pp 1-2 -
/Lead article: "Toward New Frontiers of Technical Progress"7
/Text% The Soviet people with great political and labor enthu-
siasm have greeted the First of May, the day of international
- solidarity of workers in the struggle against imperialism, for -
peace, democracy and socialism. The Soviet government in accor-
dance with the decisions of the 25th CPSU Congress is steadfast- -
ly pursuing a Leninist foreign policy, which is aimed at preserv-
- ing peace throughout the world and supporting the Just stru~gle
of peoples for freedom, independence and social progress. The
policy of peace that is being pursued by the nations of social- .
ist cooperation and their Joint struggle for detente and prevent-
ing world wide nuclear war are basic factors of international -
life and the primary pledge for the peaceful future of humanity.
On May 9, 1980, the Soviet people and all progressive mankind
solemly marked the 35th Anniversary of the Victory of the So-
viet people in WWII. The heroic victory over German fascisim
was the outstanding political event of modern times.
For nearly four years under the leadership of the Communist Par-
ty the Soviet people pursued the great Victory. They proceeded
stubbornly and purposeful.ly in overcoming unseen difficulties
and in sparing no effort and their very lives to overthrow the
agressor. Victory over German fascism and then over ~apanese -
- militarism had an enormous influence on the postwar structure of
peace. It signif~.cantly strengthened the international author-
ity of the Soviet government and led to the formation of a
world wide socialist system. The victory in WWII once again
confirmed the invincible might of the world's first nation of
socialism.
- 14 -
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_ During the posi~ar ,years the Soviet Union moved forward and mul-
tiplied its economic and scientific-technical potential beyond
measure. A developed socialist society has been created in the
- USSR and grandiose plans to create the material and technical
base of Communism are being accomplished. The USSR now accounts
for one fifth of the world's industrial production. The growth
rates of Soviet industrial production are significantly exceed-
ing similar indicators of the developed capitalist nations. The
- basic trends of the intensive and dynamic development of the So-
viet economy are now the raising of the efficiency and quality
of v~ork and the achievement of the highest final national econo-
rr,ic results with the fewest expenditures.
The steady growth of the economic and scientific-technical po-
tential of the USSR and the increased opportunities of industry
and agriculture have made it possible to significantly raise
the standard of living. During the past ten years alone per
capital rea~ income has increased 1.~-fold. More than 108 mil-
lion people (more than 40 percent of the population) have im- _
proved their housing conditions. The average monthly wage (con-
sidering payments and benefits from the public consumption funds)
- per worker was 224 rubles in 1979. Significant successes were
achieved in the field of health care, culture, education and sci- _
er,ce.
The Communist Party of the Soviet Union, true to the Leninist
principles of foreign policy, is doing everything it can to en-
sure the peoceful labor of the Soviet people and to preserve and
maintain peace throughout the world.
The elections to the supreme soviets of the union and autonomous
republics and to the local councils of workers' deputies, which
were held in February 1980, were a most important political
event in the Soviet Union. The elections once again cor~firmed
the full and unanimous support of the Soviet peopleforthe poli-
cies of the CPSU and the programs for the building of Communism
that were worked out by the 25th CPSU Congress.
The working class, the farm workers and the intelligentsia fer-
vently approve the fruitful work of the CPSU Central Committee
for the further development of socialist economy, science and
culture, for raising the material well being of the workers,
and for strengthening peace throughout the world. The elections _
demonstrated the inviolat~le unity of the Party and people and
was a true celebration of socialist demecracy.
The years separating us from preceding electians were rich in
events of enormous political importance and were marked by sig-
nificant achievements in accomplishing the decisions of the 25th
CPSU Congress and the subsequent plenums of the CPSU Central
~
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_ Committee. During this period a gigantic ;~roduction potential
was created, which has made it possible to ens~,re the gradual
development of the Soviet economy - the chief factor for the
growth of the well being of the Soviet people and for the fur-
ther raising of the Soviet defen~e capacity.
Nearly one third of the basic production assets have been mo- ~
- dernized; and new large territorial-production complexes have
come into being. The agrarian policy ~f the CPSU is steadily
and purposefully being ~?ursued. During the last four years -
agricultural gross product increased by more than 40 billion
rubles. The average annual gross harvest of grain during this
period was 209 million tons, which was almost 27 million tons
more than the averaqe annual harvest of grain in the Ninth Fi.ve-
Year Plan. -
Capital investments in the national economy during the first
four years of the Tenth Five-Year Plan surpassed 500 billion ru-
_ bles; national income increased by 16.2 percent as compared
with zhe same period in the Ninth Five-Year Plan; real per ca-
pita incomes grew by almost 14 percent; and more than 423
million souare meters of housing were commissioned.
All Soviet people perceived the speech of General Secretary
Brezhnev at a meeting with voters in the Baumanskiy election
district of Moscow as an urgent program of action at the modern
day stage.
Of enormous importance in the further realizatian of the econom- -
ic and social program of the CPSU are the decisions of the Novem-
ber (1979) Plenum of the CPSU Central Committee, and the rules
and conclusions that were contained in Brezhnev's speech at the
Plenum. -
At the November (1979) Plenum of the CPSU Central Committee they
disGUSSed the results of the development of the natianal economy
and with a Party adhexence to principle they noted the existing
shortcomings and indicated specific ways to eliminate them. The
Plenum noted that the basic trends of the achievement of highest
natioiial economic results are the further raising of the level
_ of managing the national economy, improving the economic mecha-
nism and increasing the responsibility of managers at all levels
for the fulfillment of the decisons that have been made, an~
strengthening labor, planning and state discipline at each sec-
tor of work. The mandatory fulfill~nent of the decisions of the -
November (1979) Plenum of the CPSU Central Committee is the
main task for all enterprises and organizations of the USSR Min-
istry of the Machine Tool and Tool Building Industry (Minstanko-
prom).
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Solemnly and with greatpolitical and labor enthusiasm the Soviet
~ people marked the 110th Anniversary of Lenin's birth, having
commemorated this historical event with great successes in so-
cialist competition. The collectives ~f the enterprises and or-
ganizations of the Minstankoprom, having successfully fulfilled
their anniversary socialist pledges,continue to work purposeful-
ly on fulfilling the pledges that they made for 1980. Thus, -
workers at the Leningrad P~achine T~ol Building Production Asso-
ciation imeni Ya. M. Sverdlov have decided to fulfill the as-
signments of the Tenth Five-Year Plan for volume of production
and product delivery for export ahead of schedule (by December
15, 1980).
The fulfillment of the state plan for the concluding year of the
Tenth Five-Year Plan and the creation of a production undertak-
_ ing for the successful start of the Eleventh Five-Year Plan de-
pends largely upon the further development of sacialist compe-
tition in all collectives of the sector. To make socialist com-
petition a more powerful factor for the ahead of schedule ful-
fillment of assignments for the drafting and assimilation of
- new equipment is the primary mandate of economic managers and
Party, trade union and Komsomol organizations.
On 10 and 11 March 1980 in the CPSU Central Committee there was
a meeting of the workers of htinstankoprom in connection with _
the passage of the CPSU Central Committee and USSR Council of
Ministers Decree "Concerning the significant raising of the tech-
nical level and competiveness of the metal working, casting and
wood working equipment and tools". The decree is a multi-plan
document that opens a qualitatively new stage in the development
of Soviet machine tool and tool building industry. The decree
is directed at sharply increasing the technical level and pro- -
ductivity of the machine tools, forge and press and casting
equipment and tools and significantly increasing the output of
'~he more progressive forms of such equipment in the Soiciet Union
during the Eleventh Five-Year Plan.
At the present time the USSR has a powerful machine tool and
tool building industry, which each year produces more than
300,000 metal cutting machine tools and forge and press and
casting equipment. In the Tenth Five-Year Plan serious work was
done to raise the productivity of the equipment that was manu-
factured and to change the structure of the manufactrued equip-
ment toward increasing automatic machine tools, highly-produc-
tive presses and machines, automatic production lines, and ma-
chine tools with CHPU (numerically programmed control). With
a growth in the total output of inetal cutting machine tools as
compared with the Ninth Five-Year Plan of 6.4 percent, the pro-
duction of special, specialized, modular, high precision, heavy
and unique machine tools, as well as automatic equipment, semi-
automatic equipment and automated production lines is increasing
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by 25 to 60 percent, while the outpui: of nachine tools with
, CHPU will more than double. There has been a significant growth
in the production of modern forge and press and casting, wood
~ working equipment and tools.
However, in spite of the important achievements, the technical
- development of machine tool building is still being accomplished
at inadequate rates. The structure and quality of the eq~~ipment
_ that is being manufactured for metal working do not fully meet
the tasks for the adoptior: into the machine building production
of advanced technological processes that can provide the great-
est growth in labor productivity, raising the coefficienty for
- the use of inetal and improving the quality of machine building
product.
The achievement of high technical frontiers, which were defined
by the decree, wiil require a sharp increase in the production .
of the more progressive types of equipment, in particular by
- reducing the manufacture of outmoded kinds of machine tools.
' The creative collectives of the machine tool building industry
must create nearly 400 essentially new kinds of inetal cutting
machine tools and forge and press and casting equipment during
the Eleventh Five-Year Plan.
The decree calls for the rapid development of the production of =
the more improved kinds of tools. In accordance with this it ~
is proposed to increase 2.3-fold the manufacture of tools that
are outfitted with manysided plates, to increase 9.2-fold the
manufacture of tools that have plates coated with wear resistant
materials, to increase 2-fold the manufacture of cutting tools
made of polycrystalline diamonds, boron nitride and other super
hard materials, and to increase 3.2-fold the manufacture of
tools for machine tools with CHPU and for automatic production
lines. We must constantly work to reduce the consumption of
metal in the equipment that we manufacture, to more extensively
use welded constructions and the appropriate grades of rolled
metal. Thus, the use of calibrated rolled metal for moving
screws provides a more than 20 percent savings in metal. At ~
the Kolomna Heavy Machine Tool Building Plant, the Novosibirsk
"Tyazhstankogidropress" Plant imeni A. I. Yefremov, the Krama-
torsk Heavy Machine Tool Building Plant imeni V. Ya. Chubar',
and at several other plants the welding of unique parts is being
assimilated. Moreover the weight of the parts is lowered by
20 to 25 percent; and the labor intensiveness Qf their mechan-
ical processing is significantly reduced.
The program for the further development of machine tool building
calls for the carrying out of important measures to create and
modernize production capacities. Significant amounts of money
- are being allocated for these purposes. New plants will be
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built; and existing plants will be enlarged and modernized.
At the same time personnel must be trained and the technologi-
cal preparation of production must be accomplished. -
- At present in the organizations and at the enterprises of the
Minstankoprom specific measures are being devised to fulfill the
assignments established by the decree of the CPSU Central Commit-
_ tee and the USSR Council of Ministers "Concerning the significant
raising of the techni.cal level and competiveness of the metal
working, casting and wood working equipment and tools". Many
collectives are making socialist pledges aimed at fulfilling
newm more complicated assignments for raising the technical le-
vel of their product.
All workers of the Minstankoprom with great inspiration have
perceived the decree of the CPSU Cen'tral Committee and the USSR
Council of Ministers and see it as a new manifestation of the
constant concern of the Party and gove~rnment for the development
- of machine tool building. The collectives of the enterprises -
and organizations of Minstankoprom are applying all their efforts
and cre4tive energy to fulfill the 1980 plan and the socialist
pledges that they made.
COPYRI(~iT: Izdatel'stvo Mashinostroyeniye, STANKI ~I INSTRUMENT, 1980
v -
Monitoring Devices
Moscow STANKI I INSTRUMENT in Russian No S,May 80 pp 5-8
/Article by A.A. Batalin, A.I. Kamyshev and B.I. Cherpakov:
"Basic Principles of Constructing a System for the Technical
Monitoring of Machine Tools with CHPU'_/
/Text/ One of the factors delaying the use of machine tools with
CHPU is the relatively low coefficienty of their use (the work
time of such machine tools for the control program is 40 per-
- cent of the available work time; * significant time losses are
connected with breakdowns and the recovery of working capacity). -
One way to increase the efficiency of operating machine tools _
with CHPU is the system of technical monitoring (STD). The .
creation of STD of machine tools with CHPU represents a compli-
cated multifactor task that requires the systems approach for
its solution. At the first stage of the creati~n of the STD
for machine tools with CHPU it is advisable to determine the
basic principles for its construction and lay out the overall _
- structure. In analyzing available experience in operating ma-
chine tools with CHPU one can formulate the following basic
principles of constructing an STD.
* Automatic complexes of machine tools with CHPU with centcal-
ized control from a computer for processing housing parts.
Moscow, NIIMash, 1977, 66 pages.
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1. The STD according to functions, structure and utilization
technical means must correspond to the level of production auto-
mation, in which the machine tools with CHPU are operated.
2. The STD of the individual machine tool with CHPU, which is
built into the automated production facility (sector, shop,
plant), must be included in the automated system of pro~uction
control (ASUP) and be connected with other systems by means of _
information channels.
3. The STD must be a component part of the total system for
controlling the machine tool with CHPU and be created on the
same methodological and element base with the system and must
have the capability of using common information channels for
the entire control system.
4. The STD must provide efficient monitoring when adjusting and
operating and when preparing for and performing planned repair
- of the machine tool (this article basically examines the me-
thods of technical monitoring, that are used when operating the
equipment).
5. To obtain diagnostic information maximum use must be made
in the STD of the existing devices of the control system and
provision for the functioning of the machine tool.
6. The CHPU system (including the system containing the com- -
puter) must have a self-monitoring system that is constructed
- with the use of test-programs.
Figure 1 shows a structural diagram of the informational connec-
tions of the STD of a machine tool with CHPU in an automated sec- -
tor.
Experience in operating machine tools with CHPU shows that the _
STD should be made into five subsystems: "Control of the readi-
ness of the machine tool to operate", "Operational cyclical mo-
nitoring", "Operational assembly monitoring", "Special monitor-
ing methods", and "Moni~oring of processing results". -
The work of the three first subsystems is based on the use of
means of control, made in the form of binary monitors of various
kinds. The work of the two last subsystems is based on the use
of multirange or analog monitors; in this case the functioning
of an individual system of the machine tool or of its part can
be described as transfer functions or as differential equations
(these equations are solved on the computer). In monitoring
the parameters we include the static and dynamic control, the
removal of readings, their storage in memory and the constant
statistical processing of the values received by this means.
20.
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~ ~ W ~ 2
~ _
~
~ e _
- 1S � RuNmpptexe- ~ ~ -
aaazn~acirxner~cii
9cmpuitcm0o � 15 A1 nyn~m 9
ynpaMeM~rnn 14~
KNM
'6
KNN ~ 10
Z3 J ~1
17
mQHOR `1~y 11
' ~ 18 13.
" 14
11 10 19
_ Figure 1.
Structural diagram of the information circuits of the STD of a
machine tool with CHPU in an automated sector: I- In a system
for mo nitoring the course of production; II - In a system for
preparing the UP /programmed control%; 1- External memory;
2- Monitoring algorithms; 3- Data bank on status of correct
functioning; 4- Test program monitoring bank; 5- Current
information storage; 6- Special programs; 7- Working data
- files; 8- Readout of the basic conditions of the machine tool;
9- Computer connection, test program call-up and telephone com-
munica tions with service; 10 - Call-up and signal conversion
- from the means of technical monitoring; 11 - Storage of alga-
rithms and mathematical support of the operational cyclical mo-
nitoring; 12 - Transfers of diagnostic information into the
computer; 13 - Receipt from the computer of test programs and
_ their processing; 14 - Feed of operational diagnostic informa-
~tion into the control-diagnostic panel; 15 - Means for control-
ling the readiness of the machine tool to operate; 16 - Means
- for operational cyclical monitoring; 17 - Means for operation-
al assembly monitoring; 18 - Means of adaptive control; 19 -
Signal conversion unit; 20 - Active control devices; 21 -
Manual control devices; 22 - Equipment for special monitoring -
methods; 23 - Part; 24 - Processing of incoming information,
determining the critical value of a part size, feed of diagnostic
21
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~
FOR OFFICIAL USE ONLY
(continuation of key) -
signs into the computer and the operating service; 25 - Opera-
ting service (KIM - control and measuring machine).
A - Control-monitoring panel
B - CHPU
C - P~lachine tool
D- KIM (control and measuring machine)
E - KIM control device
An automatic control of the preparation of the machine tool to
operate (it checks availability of an ingot on the machine tool,
of a tool in the magazine, the pressure in the hydrosystem, in
the SOZH (cutting fluid) feed sysi:em and in the pneumatic sys-
tem, cutting fluid in the tank, and the feed of lubricant to
the appropr~ate assemblies) is placed in the subsystem "Control
of the readiness of the machine tool to operate" (Figure 2).
Correlated information concerning the readiness of the machine
tool is removed to the monitoring panels of the machine tool
and to groups of machine tools. Information concerning the rea-
sons for the nonreadiness of the machine tool can be sent to
the controller's panel. The following means of control are
used in this subsystem: terminal circuit breakers, blocking
relays, pressure monitors, floating relays and so forth.
The subsystem "Qperational cyclical monit~ring" provides gener-
alized evaluation of the technical condition of the machine
tool and also performs an operational search of the place and
reason for a b~~eakdown or malfunction in the functioning of the
machine tool according to an assigned program with feed of in-
formation to the controller's panel; it also analyzes devia-
tions from estimated values and forecasts changes in the tech- -
nical condition of inechanisms and assemblies that are responsi-
ble for a given element in the cycle. It estimates the date
and time of lost time for organizational reasons (waiting for
ingots, tools and UP, etc.) and signals when a tool nee~ds to
- be replaced. Terminal circuit breakers, relays, feed back
monitors for position and machine tool control system timers are
_ used as control means in this subsystem.
The work of this subsystem (Figure 3) is based on a principle
that was developed by the ENIMS /Experimental Scientific-Re-
search Institute of Metal Cutting Machine Tools7. This prin-
ciple governs the control of the time of working and auxilliary
processes on machine tools with CHPU. This controls the dura-
tion of the total cycle, the elements of the basic cycle (for
example, turning the tool arm, turning the tilter of the tuol,
the indexing turn of the table, etc.), the elements of the com-
bined cycle (for example, positioning of the tool magazine) and
cutting. 22
FOR OFFICIAL USE ONLY
a
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~ 1Z . 13 =
n ~4
1 2 3 4 S 6 7 B 9?0 16 _
_ Figure 2.
Structural diagram of the STD subsystem "Control of the readiness -
of the machine tool to operate": 1- Automatic circuit brealcer _
of the machine tool; 2,3 and 4- Blocking relays of the main
- drive, feed drives and auxilliary motion drives, respectively;
5,6 and 7- Pressure monitors in the hydrosystem, cutting fluid
~eed systems and in the pneumatic system, respectively; 8 and
9_ Monitors of the level of oil and cutting fluid, respectively;
10 - Monitor showing presence of ingot; 11 - Monitoring panel _
of the machine tool; 12 - Signal switchboard; 13 - Monitoring
panel of a group of machine tools; 14 - Signal coding device; _
15 - Upper class computer; 16 - Controller's dis~,lay.
The subsystem works in this manner. When preparing the program- _
med control they estimate (based on technological data) the dura-
tion of the total cycle,'t;~ of the elements of the basic cy-
cle, ~~p of the elements of the combined cycle and '~~Pe3 of cut-
ting, which are registered in accordance with command addresses
to the program carrier, for example on punched tape. On the ba- _
sis of this information they also estimate the time of the use
of each of the cutting tools and signals when it must be re-
placed.
The program carrier is fed into the device that reads the pro-
grammed control, from which information concerning the estimat-
- ed duration of the cycle and its elements are fed into the com-
parison unit and information concerning the time of the use of
the cutting tools is fed into a unit for estimating the work
time of the tools. _
During the functioning of the machine tool signals from the -
monitors of position of the working parts pass through a unit
that controls the actual duration of the cycle elements; this
unit can be made in~the form of a control timer. The actual
durations $'1~ and't',~~ are fed into the comparison unit, where
23.
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they are compared with the estimated durations'tip and~'~p -
Information is fed into a unit for determining the actual dura-
tion Z~~ , from which the obtained result is transmitted into
a comparison unit and a device for output of information, as
_ well as into a system for estimating and planning the course of
production.
~
~ ~
` ' ~ 1 na
r-----
i t
3 q �x i
�e�. i 6 i
- ~
- ~ipe.t.p ,CEp t`P,~c~ -
fi ~
. z~m ri~
10 9 rEm 8
- dt~ dti '~r___
- ~ 11-------- - - ;
t t -
16 13 ~ ~
i ~
i ~
i 17 ~
i
~ 18 1S i
- ' ~
L____ `
' r-----~
I ~
19 10 ~ -
i '
Figure 3.
Structural diagram of a subsystem STD "Operational cyclical mo-
- nitoring": 1- System for preparing the programmed control;
2- Program carrier; 3- Reading device; 4- Machine tool with
CHPU; 5- Device for processing programmed control on the ma-
- chine tool; 6- Monitors showing position of the working parts
of a machine tool; 7- Unit for controlling the actual dura-
tion of the elements of a cycle; 8- Unit for determining the
total actual duration of cycle; 9- Comparison unit; 10 -
Tuned element; 11 - Unit for estimating work time of cutting
tool; 12 - Information output device; 13 - Unit for encoding
information; 14 - Code table of malfunctions and probability
of their happening; 15 - Unit of integral evaluation of the
_ condition of the machine tool according to Q~~ ~ dZ~ a,~(d~, ;
~
~ 24..
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(Continuation of key)
1G - Display panel; 17 - Display showing reasons for break- _
down; 18 - Command to replace tool; 19 - Operational service; F
, 20 - System for estimating and planning course of production: "
T~ pe3~ ~~';p- 'r~p and Z"fp - estimated durations of cutting, ele- -
ment of basic cycle, element of combined cycle and total cycle,
respectively; Zi�� 'Z~~� a,~d2~p - actual durations of the basic c- =
cle, element of the combined cycle and total cycle; di~'dr~~l~T~ ~
- deviations in the actual duration of the element of the basic -
cycle, the element of the combined cycle and the total cycle.
The work algorithm of the device for information output is con-
structed in the following manner. When the information encoding
unit receives a signal to the effect that the duration of a cy-
cle element exceeds what is permissible (this equates to a"mal-
- function" or "breakdown" situation in one of the cycle elements),
the display panel lights up the location of the malfunction or
breakdown in an encoded or alphanumeric form. The reason for
the malfunction is determined automatically according to a pre-
liminary logical analysis or by an operator (a representative of
the operations ser~~ice) on a table of malfunctions.
The subsystem "Operational assembly monitoring" (Figure 4~) is -
used to diagnose when the subsystems "Control of readiness of
the machine tool to operate" and "Operational cyclical monitor-
- ing" are unable to perform this task; it is used primarily when
the machine tool is not functioning properly. The assemblies
- and systems, which support the functioning of the machine tool,
- are the obJects of the monitoring; test programs are used as
the means of control for monitoring of the lower rank computer,
the means of signal output from the device for controlling the ~
feed drives, the main motion and electroautomatic equipment of
the machine tool and the con~outers of the lower and upper rank.
The monitoring is performed according to an absolute algorithm.
For this on the command from the monitoring panel the assembly
switchboard switches the malfunctioning assembly to query its
control points. From the control points the si~nals pass -
through the signal coding device, where based on a comparison
of signal levels with the established limits these signals are
- converted into logic zeroes and ones. -
At the same time a command is fed to the call-up for selecting
the fixed combir~ations of codes, which correspond to the control
points of the assembly, from the external memory device (VZU)
of the lower rank computer. According to the results of the
- comparison the matched combinations are formed. The reason for
the breakdown and recommendations for eliminating it are shown
- on the screen of the operator's display unit. When the CHPU
device malfunctions, which is installed on the base of the low-
er rank computer, the computer monitors itself; when this can-
not be done the upper rank computer is switched on.
25.
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f
_ 9
2
; 10 11
3
_ 9 8
4 12 13 11 ~
- 5
6 1k 15
f igure 4. -
Structural diagram of a STD subsystem "Operational assembly mo-
' nitoring": 1,2,3 and 4- Devices for replacing tool, clamping
the tool andreplacing the ingot and clamping the ingot, respec-
tively; 5- Feed drives; 6- Main motion drive; 7 and 8-
Switchboards for the assemblies and signals, respectively; 9
and 14 - Monitoring panEls of a group of machine tools and a -
machine tool, respectively; 10 and 13 - Computers of the upper
and lower ranks, respectively; 11 - Computer external memory
units; 12 - Signal encotling device; 15 - Operator's display. -
The subsystem "Special monitoring methods" is used to perform
complicated operations of monitoring using special tests and
devices, the presence of which on the machine tool for techni-
cal and economic reasons is inadvisable. The subsystem is used
when the operational monitoring does not make it possible to es-
tablish the reason for the machine tool not functianing proper-
ly and also to forecast the working capacity of the machine
tool an.d performing preventive work for technical servicing.
In contrast to the subsystem "Operational assembly monitoring"
in this subsystem the monitoring i~ performed primarily by
using analog signals of working processes that take place in
the machine taol and also the signals from ~onitors that are
- built into the machine tool. Both the electrical and the
26.
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mechanical parameters of the systems and assemblies of the ma-
chine tool are analyzed. As a rule, monitoring is carried out _
according to an arbitrary algorithm, i.e., each subsequent
check is set consirlering the results of preceding checks. In
this subsystem the following means of control are used: the
. switching electrical instruments, built-in guages of inechani-
cal parameters, an installed control and measuring rigging,
test programs for controlling the machine tool, equipment for
the output and registration of diagnostic information, and an -
upper rank computer.
Due to the setting of differentiated norms for various signals,
statistical processing, sQectral analysis and other forms of da-
ta processing, the subsystem defines and analyzes the technical
characteristics of the machine tool which affect its working ca-
pacity (precision of positioning, the precision of the circum-
vention of a contour, the frequency characteristics of the
drives and the carrier system, the geometric precision of the
machine tool, and so forth). The subsystem controls the mechan-
ical para~neters of the elements of the design of the machine
tool as well (the rigidity of the kinematic pairs, the clear-
ances, the force of friction, wear and so forth). Additional
installed devices and instruments for the initial processing .
of signals are installed on the skid-base and are connected with
the machine tool by channels of communication.
An upper rank computer is used for the monitoring. The required
_ test program for controlling the machine tool is summoned from
the external memory device and transmitted to the lower rank com-
puter. At the same time the reference values of the signals
and the programs for their processing are retrieved from the
external memory device. The signal switchboard (for inputting
the latter into the ,~n~~cg-diyital converter) is controlled ma-
nually or automatically (through the feed of commands from the
lower rank computer in accordance with the test program for con-
trolling the machine tool). The obtained diagnosis is fed to
the operator's display panel. As concerns the directinput of
the experimental data into the computer of the upper rank it is
possible to use an intermediate carrier of information in the
form of magnetic tape of punched tape. This method is somewhat
more simple than what has been described, but it is less effec-
tive.
- During preventive maintenance checks the obtained characteris-
tics of each machine tool is stored in the external memory de-
vice of the upper rank computer, where also information is kept
about the time of operation and the repair of assemblies and
systems of the machine tool. Based on the analysis of the
changes in the characteristics and their comparison with the
normative values the predict the probability of maintaining the
working capability of the machine tool for a certain period of
time.
27.
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The basic task of t he subsystem "Monitoring according to pro- -
cessing results" is to control the changes in the status of the
_ assemblies of the machine tool, which affect the precision; of
the parts that are processed. This subsystem is particularly
important for the t echnical monitoring of machine tools with
CHPU for finishing processing. In this case the errors in geo-
metry of the machin e tool and its change under external fac-
tors (fall in the t emperature of the air and floor, deviations
in the foundation, etc.), wear of the moveable assemblies, the
heating of base par ts, etc., are basically copied on the part
~ being processed.
The re.sults of test s performed at the Experimental Scientific-
- Research Institute of Metal Cutting Machine Tools on MA690MF4
model machine tools demonstrated that the information that is
obtained when measu ring marts following finishi~g work has se-
veral diagnostic in dications. For example, during the finish-
- ing work of a surfa ce using a face cutter, equipped with cut-
ting tools made of elbor, on the surface of the part being pro-
cessed was "imprint ed" that which at the high frequency of re-
_ volution of the spi ndle (n 1000 RPM) under the influence of
thermal. separation from the supports of the spindle the axis
of the latter is displaced relative to the directing (a length- .
- ening of the spindl e takes place in the direction of the part
and its angular displacement), ~
Within the limits o f time of processing of the surface the leng-
thening of the spindle took place at a speed of e s/B -
6 micrometers per m 3nute. The angle of deviation af the axis of
the spindle under t he effect of thermal deformations at the end
of processing was d =arctg /h/Dfr1000%. Here Q is the non-
rectilinearity of t he surface being processed in micrometers;
s- is the feed in millimeters per minutes; B- is the width of
the part in millime ters; h- is the depth of the tread obtained
when milling in sev eral passes along the height of part in micro-
meters, and Dfr is -~he diameter of the cutting in millimeters.
Consequently, if fo llowing this processing the error in the sur- -
face exceeds what i s permissible, it is necessary to check the
supply of lubricant to the ballbearings of the spindle, the tem-
perature of the oil in the lubricating system, the correctness
of the regulation a f the clearance in the bearings of the forward
. support.
The analysis of the change in parameters in time makes it possi-
ble to predict the advancement of the critical condition of the
machine tool and to plan timely technical servicing or repair. -
One of the methods for predictin~ an emergency situation or the
28
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need for servicing is examined in the work cited below. ~ This
method is based on determining the fact of the outcome of the
drift curve of the centers ior grouping the controlled size
(for example, the size of an opening being bored) within its
maximum value. The cited stzucture of the STD predetermines
_ the sequence of monitoring the technical condition of a machine
tool with CHPU. (Figure 5)
Figure 5. Algorithm of sequence
~ S~?~T~e�r, for monitoring the technical con-
BKmarcHae dition of a machine tool with
NO CHPU. 1- Subsystem "Control of
2 ~o~ readiness of machine tool to op- _
ES erate"; 2- Is there a signal
3, showing readiness of machine taol
to operate; 3- Machine tool
~ t2 starter; 4- Switch for turning
~E~ on the the subsystem "Operation-
s ~3 - al cyclical monitoring"; 5-
- Is there a "Breakdown" signal;
- ~y 6 - Continuation of functioning;
VEs 7- Removal of finished part;
_ 6 is 8- Control of part on the KIM
-~No /control and measuring machine%;
~s 9- Is there a signal "Part is
useable"; 10 - Summons to the -
- control-monitoring panel; ~1 -
7 -
rd Elimination of malfunction; 12 -
Search for place and cause of
8 19 breakdown; 13 - Is there a sig-
nal "Breakdown eliminated"; 14 -
1~ Switching of the subsystem
No.
9 p~ "Operational assembly monitoring"; -
I 15 - Is there a signal "breakdown
eliminated"; 16 - Service call;
17 - Switching of the subsystem
� "Special monitoring methods: 18 - -
Carrying out of monitoring; 19 - Is there a signal "Working ca-
pability established"; 20 - Decision making concerning perfor-
mance of repair work; 21 - Switching of subsystem "Monitoring
according to results of processing": I- Into the system for
estimating the course of production. -
Information of the diagnostic system can be used as initial da-
ta for other systems working within the automated production
control system, in which are used machine tools with CHPU. For
~ Kardanskiy~ L.L., Naydin Yu.V., Chudakov A.D.: Centralized con-
trol of machine building equipment from a computer. Moscow, Ma-
shinost~oeniye, 1977, 263 pages.
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the system for est i rnating the course of production the STD can
transmit the follo wing information: actual duration of part
processing on each machine tool and each Qperation, duration of
standdowns for var i ous reasons, productivity of each unit of
equipment and predi ction of the working capability of the basic
assemblies of the machine tool.
Information concern ing the duration of standdowns due to break-
downs, malfunction s, scheduled and unscheduled maintenance, fre-
quency of malfunct i ons for each unit of equipment, etc., is fed
~ into the system fo r estimating and analyzing the reliability of
the equipment. Inf ormation concerning mistakes in programming,
the need to change the processing mode (based on the analysis
_ of the frequency of breakdowns of the cutting tool), the number -
of motions, and so forth is fed into the system for preparing
the programmed con t rol.
With consideration of the obtained diagnostic information these
systems perform nec essary estimates, on the basis of which the
system of operation al-calendar planning enters the algorithm of
production control into the monitoring system.
_ A structural diagra m of the STD connections with the ASUP /auto-
mated production co ntrol system/ is shown in Figure 6.
Figure 6. Structural diagram of
the STD connections with the
1 ASUP systems: 1- Monitoring
system; 2- System of operation-
- ~ al-calendar planning; 3 - Sys-
Z tem for preparing the programmed
- 6 control; 4- System for rating
3 5 the course of production; 5-
' ~ System for rating and analyzing
equipment reliability; 6 - Mo-
7 nitoring center; 7- STD termi-
nal; 8- STD; 9- Means for
8 monitoring; 10 - Information �
panel; 11 - Production equip-
ment. _
9 9 9
10 11
Experience in using machine tools with CHPU, the analysis of the
reasons for breakdo wns and the time structure of using such ma-
chine tools demons t rate that the adoption of STD makes it possible _
- 30
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to significantly increa~e the coefficient of using machine tools -
- thereby raising their productivity. The economic savings from
using STD and each of its subsystems can be determined according
_ to the formula E9 = Tsl (1 - KuP2V2 - Kor9)/(1 - Kupl~l Korg)
- Ts 2+/F~S/(R + Ye~)% X(K~P1V1 - K~P2V2), where E9 is the
annual savings from using STD in rubles; Tsl and Ts2 are the
wholesale prices of the machine tool before and after adoption
of the STD in rubles; K~P1 and KUP2 are the coefficients esti-
mating the work of the machine tool according to programmed con- -
- trol before and after the adoption of the STD; V1 and V2 are
the relative durations of restoration before and after the adop-
tion of STD; Kor9 - is the coefficient that estimates organiza-
tional and technical losses; F~ is the nominal time fund under
a two-shift system; Yen is the standard efficiency coefficient
(Ye~ + 0.15); R is the norm of amortized deductions for equip-
ment restoration (R = 0.053); and S is the cost of one hour
- of unscheduled repair in rubles. -
The first two members of the formula estimate the savings from
raising productivity by increasing the coefficient of use of
the machine tool; the third member is the savings from reduc-
ing losses in expenditures for unscheduled repair work.
According to data cited below ~ the STD is compensated if, for
example, the time of breakdowns o~ a multi-tool machine tool
with CHPU is reduced by 10 to 20 hours per year altogether.
- * Hollingum Regular check-ups for your computer can keep _
it on its feed. - tngineer (Gr. Brit), 1975, 240, N 6210, p
47 - 49.
COPYRIC~T: Izdatel'stvo Mashinostroyeniye, STANKI I INSTRUMENT, 1980
v -
New Line of Milling Machines
, Moscow STANKI I INSTRUMENT in Russian No S,May 80 pp 9- 10
/Article by N.I. Ivanov, I.N. Solovyev and N.M. Syundyukov:
"A New Group of Milling Machine Tools witti CHPU for Pracessing
Ships Propellers'_/
/Text% One of the most labor intensive operations in manufac-
turing one-piece propellers is processing rectilinear surfaces -
(blade~ and their plenum and suction surfaces, channeled tran-
~ sits and the external surface of the hub).
- 31
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The Leningrad Special Design Bureau of Heavy and Unique Machine
Tools has developed a line of milling machine tools with CHPU
for processing the one-piece ships propellers with a diameter
of D= 600 s 4~00 millimeters, which includes machine tools
mode~ KU350 (for D~ = 600 : 1~00 millimeters), KU351 (For D~=
- 1000 2500 mm) and KU352 (for D~ = 2000 s 4500 mm). These
machine tools are manufactured by the Kolomensk Heavy Machine
Tool Building Plant.
The new line of machine tools can be used in by-unit, small-
series and series production and are to be used for processing -
in an automatic mode of all rectilinear surfaces of a propeller, _
incuding the surfaces of the hub, the channeled transits and
edge contours. The basic type of processing of the surfaces of
blades is the face milling by maintaining a constant angle of
the inclination of the milling to the surface being processed,
by which the component cutting forces of Rx and RZ are directed
along the blade of the propeller (toward the greatest rigidity).
The remaining surfaces are processed by cylindrical and termi- _
nal cutters.
The component assembly of the line of machine tools is done con-
sidering the condition of the least departure of the tool holder
with the milling heads. Departure is determined by the ratio
of height h of the hub of the propeller to D~. For propellers
with a diameter of D~ = 600 + 2500 mm h/D~ = 0.8 f 1 predomi-
nates, while for propellers with D~ = 2500 f 4500 mm h/D~= 0.15
{.5, therefore the machine tools models KU350 and KU351 have
a radial input of th~ cutting tool and machine tool model KU352 -
is a vertical (axial).
Machine tools models KU350 and KU351 (Figure 1) are identical in
design and are made according to the type of single-column ma-
_ chine tools with a revolving table Y for the placement and se-
curing of an article 2(propeller). The mount 9 has _ mutually
perpendicular guides, on which the sledges are installed 10,
which carry the table 1, and the column 7. The column has ver-
tical guides; on which are installed the skids 6, which support
the drive drill chuck 8, which can turn in a vertical plane.
Within the casing of the drill chuck 8 is installed (on sliding
bearings) a bushing, on the forward face of which is secured
the tool holder 5, which bears a replaceable spindle head 4
with the cutter 3. Within the bushing there is a drive shaft,
which transfers the revolution from the electric motor of the
main drive to spindle of the head 4.
32
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7
6
Q
Z
-
~ 3 4 f
2 ~ \ ~ B 1
`11?: V
- 7
Figure 1. Diagram of a Model
x..-..-- KU351 Machine Tool
f0 9
These machine tools work in the following manner. The revolu-
tion of the table 1 displaces the surface of the propelle~ be-
ing processed.2 in relation to the cutter 3. The displacement
of the cirive drill chuck 8 to the cutter transfers motion in
a vertical direction (in respect to the profile of the propel-
ler blade in a given section). At the same time the tool hold-
- er 5, and consequently, to the spindle box with the cutter is
sent the revolution around the lengthwise axis, which results
in the cutter being perpindicular to the surface being pr oces-
sed. For transferring to the sledge 10 a perioc~ical feecD is
supplied. During processing by displacement of column 7 the
cutter is displaced from the center of the propeller 2, there-
by ensuring constancy in the line width.
In contrast to machine tools models KU350 and KU351, machine
tool model KU352 (Figure 2) is a non-moving table 9 and a column -
2, having a cross bar 4 with horizontal guides. On these guides
are installed a sledge 5 with a vertical slide bar 3. On the
lower face nf the slide bar a turning spacer 6 is installed,
. the mooring surfaces of which are placed at a 15 degree a ngle
to each other. To the lower surface of the spacer 6 is attach-
ed a drill chuck 7, within which is placed a turning bushing.
On the forward face of this bushing are installed replaceable
spindle boxes 1 with cutters 8.
- z_ s
4 -
",~1' , = f~.-
2 � ~~X
= '~h~.
~ ~ ~ Figu~~e 2. Diagram of a Model
v'F' Machine tool
r~ B
- '
~
6
I II
. 9 a ~ 33
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The spacer 6 can be turned in relation to mooring surface of the
slide bar 3 that is connected with it, and the drill chuck 7 can
be turned in relation to the slanted mooring surface of the spac-
er 6, which makes it possible to change (in a vertical plane)
the angle of inclination of the lengthwise axis of the drill
chuck 7 and to install the cutter in relation to the radial
slant of the blade. Turning the spacer 6 only in relation to
the upper mooring surface puts the lengthwise axis of the drill -
chuck 7 and the cutter in such an angular position in an hori-
zontal plane, which ensures passes of the spindle box 1 in the
inter-blade space of the propeller.
The spindle drive is accomplished from the electric motor
through the two-stage speed box and the drive shaft, that is
located in the bushing. Machine tool model KU352 works in the
same way as models KU350 and KU351 with the single difference
that the feed to an~ther line is done by the movement of the _
sledge, and the displacement of the cutter from the center of `
the article is done by turning the spacer.
The necessary values of displacing the assemblies of the machine
tools of this line during their operation are supplied by a pro-
gram written on punched tape, from a CHPU device type N55-2.
On machine tools models KU350 and KU351 CHPU control is done in
accordance with five coordinates (See Figure 1): X- displace-
- ment of the table; Y- displacement of the column; Z- dis-
placement of the drill chuck; S- revolution of the table; D-
revolution of the bushing with the tool holder. Coordinate V
is the turning of the drill chuck is adlustable; displacement
is accomplished manually (using a scale). _
On machine tool model KU352 the CHPU control is performed in
accordance with four coordinates (See Figure 2.): X- the dis-
placement of the sledge; Z- displacement of the slide bar;
_ D- turing of the bushing with a head; S- the turning of the
table. Coordinates Ye and V- the turning of the drill chuck in
horizontal and vertical planes are adJustable; displacements
are done manually (using a scale).
On machine tools of this line all coordinates, that are control-
led by a CHPU, have a digital display, and linear coordiates
X, Y and Z also have zero creeps.
' DC electric motors with a broad range of regulation are used
as main drives, which in combination with the two-stage speed
boxes and three types of replaceable spindle boxes provide for
the processing of all these surfaces of propellers made of va-
ri.ous materials.
34
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~ In the feed drives they use DC electric motors with a power
supply from thyristor converters. The feed drives of linear
coordinates X, Y and Z contain reducers with a transmission ra-
tio of 1: 7.5 and ball-type pairs of propeller to screw of
100 X 12 mm. The feed drives of the circular coordinates S .
and D have terminal linds - worm pairs with a variable screw.
For feed back monitors they use revolving transformers of the
VTM-1V type.
Tests of the KU350 machine tool (on specimens) have demonstrat-
ed the stable cutting and required 0.1 mm) processing accura-
cy, inspite of a significant (750 mm~ departure of the tool
holder. In Figure 3 we see a profilogram of a round specimen
that was processed on a KU350 (with a non-moving table, by means
of movements along the X and Y coordinates) by means of terminal
cutting with a diameter of 50 mm, six teeth made of R18 high-
speed cutting steel. Processing mode: cutting depth of 10 mm;
cutting width of 15 mm, and cutting speed of 40 meters per minute.
The radius of the equidistance is 160 mm; and the specimen was
- made of steel 45 (NB 170).
Y~
Figure 3. Profilogram of a
~ circular specimen processed on
KU350 machine tool. The solid -
_ x line is the processed contour.
~ ~ The broken line is the assigned
~ contour (the arrow shows the di-
- ~ rection of contour by-pass) .
~ /
As you can see, the greatest error in processing occurre~ in the
direction of the Y coordinate; this error was caused by a trans-
- verse deflection of the tool holder from the force of cutting.
The affect of the dynamic error of the machine tool's feed
drives on processing accuracy is insignificant. The surfaces
of the propellers generally have smooth contours and allowances
for processing vary only slightly. This results in a constancy
of the curve angle of the tool holder, which in turn raises pro-
cessing accuracy. -
- 35
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The described machine tools make it possible to process pro-
pellers with a constant and variable step; while forming blades
it can have an inclination of up to 75 degrees and a variable
curvature.
The use of face milling in combinat~on with programmed control
along four to five coordinates inproves cutting conditions and
raises the durability of the tool and the productivity and sta-
bility of the form of processed surfaces; it reduces thea.r
roughness and, as a consequence, improves the op~rating charac-
teristics of propellers.
~ COPYRIGHT: Izdatel'stvo Mashinostroyeniye, STANKI I INSTRUMENT,
1980
8927
- CSO: 1821 END
36
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