3D Vibration Machine Tool and New Technologies at its Diversified Application.

Author: V. Chebyshev
3D Vibration Machine Tool (VMT) is developed and proposed for wide industrial and residential use.

VMT is of an original design providing non-impact vibration and stable vibration features regardless the working area duty (within the limits of carrying capacity). Besides vibration of the working area and vibration object go on simultaneously in two mutual perpendicular surfaces - vertical and horizontal. Thus, 3D (complicated) vibration is generated with powerful multivector dynamics of effect. Vibro-processed object fixed at the working area receives much activating energy (not less than 17,43 joule per time unit at a unit mass).

Initially VMT was developed for its application in casting industry to increase the quality and maintenance features of shaped castings. It is known that the promising way of casting industry development is in the upgrade of qualitative indices on account of high resistance, high efficient and environment-safe technologies, computer projecting of the production, up-to-date accessories for technological processes is.

New technology based on 3D vibration principle with respect to casting industry is quite efficient and allows for higher quality if compared with other casting methods, including simple vibration, i.e. casting into vibrating forms at the vertical motion.

High efficiency is reached on account of:

• Rejects reduction from average 5% (sometimes 15-17%) down to 1% and less;
• Rise of usable castings output from average 55% up to 70% and more (for steel).

It allows for saving of not less than 13,6% per tone of usable castings.

Some general data on shaped casting are shown below where 3D vibration significantly enhances mechanical and maintenance features of castings at improved economic production parameters:

• Casting of turbine blades without additional accessories;
• Casting of high-quality thin-walled parts (0,5-2 mm);
• Cast iron crankshafts for engines;
• Casting of parts with 100% impermeability;
• Casting of wheel disks with increased durability not less than 150% from Aluminum alloys
• Other

New technology provides capabilities in creation of casting independent direction - "Vibration Casting". Parts manufactured by vibration casting are second to none of forged or punched parts regarding mechanical and maintenance characteristics, because crystallization quality of cast metal becomes controllable.

Vibrocasting significantly enhances the capabilities of casting industry and its prestige in the machinery.

New technology is easy from the point of application and use. VMT has no analogues both from the point of design and effect. The VMT working area is free from dissonant efforts. Working drawings are available for manufacturing of a machine with a carrying capacity of 200 kg (VMT-200). In fact it is possible to manufacture a machine of any carrying capacity using the developed calculation method

Some examples of diverse VMT applications:

• Complex vibration trial of units and equipment;
• Generation of perfect and high-strength structure of cast metal with ultra-fine grain;
• Casting of the samples of small and middle assortment omitting thermo mechanical limit of ingots;
• Obtainment of cast magnets of the enhanced quality;
• Obtainment of mixed alloys with special physical, chemical and electrical features;
• Casting of multi-layer bells with sharply enhanced acoustic characteristics, etc.

Other examples of VMT applications as a generator of activating energy:

• Healthcare (general and local therapy);
• Winemaking (acceleration of the fermentation process);
• Mechanical chemistry (intensification of the chemical process);
• Household chemical goods (accelerated blenders, laundry washer, and dish washer, etc.)

VMT functional capabilities with respect of metal melts you can learn from V. Chebyshev's article "Vibrocasting", Machine Tool Engineering, 1999, # 3 (21)

VMT Design is patented (Russian Patent # 2078643).