Hardening Process Research Articles

DLHEnhancing tribological properties of involute gear teeth through discrete hardening treatment using a biased laser source with axis

Traditional methods for enhancing surface fatigue in gears are limited by their techniques and processes, making it increasingly challenging to achieve a balance between strength and toughness and meet the demands for fatigue-resistant manufacturing of high-energy-density gears. In this study, a novel tooth surface laser discrete strengthening method is proposed, focusing on validating the actual effects of laser discrete processing and strengthening on the involute gear tooth surface. Through comprehensive simulations and experiments, the consistency and feasibility of the process within a tilt angle range of 0 to 30° are demonstrated. To address laser interference between adjacent gear teeth, a processing technique is introduced that involves the offsetting of the laser beam from the gear axis and the tilting of the optical path relative to the normal of the tooth profile. By deriving the coordinates of evenly distributed points on the involute gear profile, a strategy for biased discrete hardening processing is formulated. Furthermore, remarkable benefits are revealed through friction experiments conducted on physical gears processed using this technique, including the reduction of friction power (9.36 % to 27.10 %), the stabilization of output torque, and the improvement of substrate protection, thus confirming the effectiveness of this technique in resisting contact fatigue damage. Valuable insights into advancing the field of fatigue-resistant gear manufacturing through the utilization of laser-based discrete hardening techniques are provided by this research.

Development and verification of material models in modeling of wave strain hardening and additive synthesis processes

BACKGROUND: The creation of competitive machine parts capable of withstanding standard and increased operational loads is an urgent task in mechanical engineering. Developing additive synthesis technologies together with strengthening technologies make it possible to create such products with high load-bearing capacity. However, to improve the efficiency of these technologies, it is necessary to create theoretical models of the processes taking place. The article presents the results of the first stage of creating complex theoretical models of the combined 3DMP process and wave strain hardening (WSH) required for designing technological processes for manufacturing engine parts and brake systems of automotive equipment. . AIMS: Creation and assessment of the adequacy of material models used in finite element modeling of additive synthesis processes with subsequent hardening. MATERIALS AND METHODS: Theoretical models of the material were created in the ANSYS software package, which allows for multidisciplinary calculations. The experimental data required for preparing the models were obtained by testing tensile samples manufactured using standardized methods. The hardness of materials was studied using a KB 30S automatic hardness tester. The adequacy of additive synthesis modeling was assessed based on the distribution of temperature fields. The adequacy of material models for the VDU process was assessed based on the sizes of individual plastic indentations and the distribution diagrams of the depth and degree of hardening in the surface layer. RESULTS: Theoretical models of the following materials were developed: steel, stainless steel, bronze alloy, titanium alloy, aluminum alloy. The theoretical data obtained from the modeling results have a high level of significance. The studies were conducted for various thermal (in the range from +20ºС to +800ºС) and deformation modes. Graphical results of theoretical and experimental studies allow us to obtain a qualitative assessment of the processes under study with the required accuracy. CONCLUSIONS: As a result of the assessment of the adequacy of the developed models, it was established that the discrepancy between the empirical and theoretical data does not exceed 7.4%. The obtained models of materials are statistically significant and can be correctly applied in further studies.

Hyperbolic Evolutionary Model for Equivalent Modulus of Sand and Characterization of Its Cyclic Hardening Properties

The cyclic hardening characteristics of soil hold significant importance for understanding its performance, and the evolution of the deformation modulus serves as a crucial indicator of the hardening properties. Deformations can be classified into elastic and plastic deformations and expressed in terms of modulus; however, their roles in the cyclic hardening process remain unclear. In this study, the elastic and plastic moduli were separated using the hyperbolic evolutionary model, which characterized the evolutionary properties of both to reflect the cyclic hardening process. A series of cyclic triaxial shear tests was conducted utilizing ISO sand and emery as test materials. A hyperbolic evolution model relating the equivalent modulus to the number of cycles was established, and the effect of various test conditions on the elastic modulus is discussed. The results indicate that: (1) the relationship between the equivalent modulus and the number of cycles is hyperbolic; and (2) the parameters k and b of the hyperbolic evolution model correspond to the elastic and plastic moduli, allowing for the separation of the evolution of both from that of the deformation modulus. The hyperbolic evolution model of the equivalent modulus proposed in this paper offers new insight into the cyclic hardening properties of sand.

Butterfly-Inspired Multiple Cross-Linked Dopamine-Metal-Phenol Bioprosthetic Valves with Enhanced Endothelialization and Anticalcification.

Valve replacement is the most effective means of treating heart valve diseases, and transcatheter heart valve replacement (THVR) is the hottest field at present. However, the durability of the commercial bioprosthetic valves has always been the limiting factor restricting the development of interventional valve technology. The chronic inflammatory reaction, calcification, and difficulty in endothelialization after the implantation of a glutaraldehyde cross-linked porcine aortic valve or bovine pericardium often led to valve degeneration. Improving the biocompatibility of valve materials and inducing endothelialization to promote in situ regeneration can extend the service life of valve materials. Herein, inspired by the hardening process of butterfly wings, this study proposed a dopamine-metal-phenol strategy to modify decellularized porcine pericardium (DPP). This is a strategy to make dopamine (DA) coordinate trivalent metal chromium ions (Cr(III)) with antiplatelets (PLTs) and anti-inflammatory properties, and then cross-link it with tea polyphenols (TP) to generate a valve scaffold that is mechanically comparable to glutaraldehyde-cross-linked scaffolds but avoids the cytotoxicity of aldehyde and presents better biocompatibility, hemocompatibility, anticalcification, and anti-inflammatory response properties.

Cold nuclear matter effects on azimuthal decorrelation in heavy-ion collisions

Abstract The assumption of factorization lies at the core of calculations of medium effects on observables computable in perturbative Quantum Chromodynamics. In this work we examine this assumption, for which we propose a setup to study hard processes and bulk nuclear matter in heavy-ion collisions on the same footing using the Glauber modelling of heavy nuclei. To exemplify this approach, we calculate the leading-order corrections to azimuthal decorrelation in Drell-Yan and boson-jet processes due to cold nuclear matter effects, not considering radiation. At leading order in both the hard momentum scale and the nuclear size, the impact-parameter dependent cross section is found to factorize for both processes. The factorization formula involves a convolution of the hard cross section with the medium-modified parton distributions, and, for boson-jet production, the medium-modified jet function.

Application of Modern Machine Diagnostic Systems to Improve Safety in the Underground Mining Process

Abstract Currently used machine diagnostic systems are based on very modern solutions based on the acquisition and recording of their operating parameters in real time. Increasingly available and high-tech sensor systems mean that the number of recorded parameters is increasing and their quality is improving. These data are mainly used to assess the technical condition of machines and the processes they perform. In mining, these data can also be used to assess and, at a later stage, improve the safety of the underground mining process. Referring to this issue, the paper presents examples of the use of diagnostic systems for powered roof supports and longwall shearers to assess the safety status of the underground hard coal mining process. In the case of the wall support, the focus was on measuring the pressures in the stands of its individual sections. Temporary changes in the values of these pressures constitute a valuable source of information regarding the interaction of the support with the rock mass. In particular, this concerns the identification of the effects of the informational impact of the rock mass on the longwall excavation protected by the support. The research results presented in the paper, especially in the case of very dangerous dynamic impacts, indicate the possibility of both diagnosing the operating condition of the section and identifying symptoms of exposure to such events. This undoubtedly significantly expands the possibilities of using the measured pressures. Diagnostic signals from a longwall shearer are also widely used. The current intensities drawn by its motors while cutting the rock mass, as well as the advance speed and its position in the wall make it possible to analyze these parameters and their changes before, during and after the occurrence of various types of events. These data enable the assessment of the effects of the rock mass on its operational efficiency and safety status. It also enables the identification of symptoms that precede the occurrence of such events. The presented examples indicate the need for a broader and more holistic approach to the use of diagnostic parameters of mining machines. In particular, this concerns the study of the cooperation between the support and the rock mass and its influence on the efficiency and safety of the rock mass mining process. The subject matter addressed relates to very important and current issues, and the developed methodology and obtained results should be applied in practice as soon as possible.

Research on the Anchoring Performance of Green and Low-Carbon Anchoring Materials for Urban Rail Transit Foundation Pit Engineering

Abstract. Currently, most anchoring materials used in engineering are ordinary cement mortar, which has a slow hardening process, a prolonged early strength development, and high carbon emissions. In response to this, this paper proposes a new type of green anchoring material. The anchoring performance of this material is verified through indoor and field tests. Indoor tests on the basic properties of the green anchoring material were conducted, determining the optimal water-material ratio to be between 0.25 and 0.30 through tests on fluidity, setting time, and compressive strength. Field tests studied the ultimate bond strength of the new green anchoring material in typical soil-rock composite strata in Qingdao, confirming its rapid-setting and high-strength anchoring characteristics. The application of this anchoring material can reduce carbon emissions and realize the concept of green and low-carbon environmental protection.

Using acoustic emission to understand the early-age reaction and cracking evolution of alkali-activated slag-brick powder paste

Real-time monitoring and accurately understanding the continuous occurring psychical-chemical characterization during the hardening process of alkali-activated materials present a formidable challenge. In this study, the early-age reaction process of alkali-activated slag-waste brick powder paste (ASWP) was in-situ and continuous monitored by using acoustic emission (AE) system and temperature. A novel machine learning method was employed to categorize the evolution of AE signals into three distinct stages: reaction acceleration, reaction stabilization and volume shrinkage stage.During reaction acceleration stage (0-2h), the waste brick powder (WBP) increased AE counts rate (4000-7300 counts/h), with RT values exceeding 200μs, indicating the settlement of WBP. Additionally, WBP reduced the high r-value AE activity in volume shrinkage stage, effectively mitigated the drastic volume shrinkage, and delayed its occurrence time by approximately 4 hours. Semi-quantitative analyses of FTIR and TG-DTG indicate that WBP reduced gel phase formation in the early-age stage, decreasing the relative areas in Q2 site by 16% before 36 hours. However, WBP positively impacted ASWP hydration at long ages, increasing Q2 site d areas by 60%-100%. AE technique offers a new perspective for in-depth understanding of the reaction mechanism and microstructural development of alkali-activated materials in situ and continuously.

Deformation mechanisms of AZ31 Mg alloy sheet assisted by electrical pulse- ultrasonic composite energy field

Ultrasonic vibration and pulsed current can achieve energy concentration and effectively improve the forming ability of Magnesium alloy sheets. The uniaxial tensile tests of AZ31B sheets assisted by electric pulse, ultrasonic and electric pulse-ultrasonic composite energy fields were carried out, respectively. The influence of the effective current density and duration of the electric pulse on the softening, hardening and residual effects in the deformation process caused by the coupling action were explored. The electric pulse suppresses the promoting effect of ultrasonic vibration on twinning and together with ultrasonic vibration promotes dislocation slip to coordinate deformation. The composite energy field can thus further reduce the deformation resistance. The softening, secondary hardening and residual softening phenomena caused by the electric pulse-ultrasonic composite energy field become more and more significant with the prolongation of duration. When the ultrasonic field with a frequency of 21 kHz and an amplitude of 10 μm is combined with a frequency of 600 Hz and the effective current density increases from 0 to 30 A/mm2, the influence on the softening and secondary hardening process exhibits an initial increase followed by a decrease as the current density increases, while the influence on the residual softening shows the opposite trend.

Boronize Coatings Studied with a New Mass Transfer Model.

This study examined the development of Fe2B (diiron boronize) coatings on the surface of 35NiCrMo4 steel through the thermochemical surface hardening process called boronizing. The morphology and thickness of the boronize coatings were assessed using Scanning Electron Microscopy (SEM) and optical microscopy (OM). A novel mathematical mass transfer model was developed to estimate the diffusion coefficients of boron in hard coating. The presence of uniformly distributed boronize coatings with a typical sawtooth pattern on the surface of the substrate was confirmed. The boronize coating's chemical composition and phase constituents were analyzed utilizing X-ray energy dispersive spectroscopy (EDS) and X-ray diffraction analysis (XRD). The study confirmed the presence of a single-phase boronize coating (Fe2B). Furthermore, microhardness tests indicated that the boronized specimen's surface demonstrated an average hardness of approximately 1953 HV. The wear study were conducted using the pin-on-disk method under dry debonding conditions at room temperature to estimate the coefficient of friction (COF) of the boronized (average ≈ 0.35) and untreated (0.725) specimens. The results revealed approximately 200% improvement in wear resistance due to the boronized coating. The empirical validation of the mathematical model was carried out for two additional boronizing conditions at 1223 K for 3 h and 1273 K for 1.5 h, resulting in an estimated percentage error of around 2.5% for both conditions. Additionally, an ANOVA analysis was performed, taking into account the temperature and time factors. The findings indicate that both factors exert a substantial influence on the dependent variable (u), with temperature (T) contributing 64.68%, time (t) contributing 27.37%, and the interaction of both factors (T × t) contributing 5.13%.

Surface Mechanical Property Prediction and Process Optimization of 18CrNiMo7-6 Carburized Steel Stator Guide Based on Radial Basis Function Neural Network and NSGA-II Algorithm

The carburizing process is a key technology that affects the mechanical properties of the surface of the hydraulic motor stator guide rail, and the related process parameters have an important influence on surface hardness, the thickness of the carburized layer, and the deformation of the guide rail. However, at present, the relationship between the carburizing process parameters and the surface mechanical properties of the target is not clear. This paper proposes a “hardness prediction and process parameter optimization” method. Firstly, a finite element model is established, with carburizing time, temperature, and carbon potential as the three input factors; the optimal Latin hypercubic experimental design and sensitivity analysis are applied. Secondly, surface hardness, carburized layer thickness, and deformation are taken as the output values, and an RBF neural network is used to construct the prediction model. The results show that the RBF neural network can be accurately used for the prediction of surface hardness, the thickness of the carburized layer, and deformation, and for the optimization of process parameters. The optimized parameters of surface hardness and the thickness of the carburized layer were increased by 4.2% and 5.1%, respectively, and the deformation amount was reduced to 0.31 mm, achieving the goal of optimal design.

Buckling behaviour of high-strength retrofitted steel sections manufactured through post heat-treatment processes

High-strength steel is increasingly popular in construction for its strength-to-weight ratio, which lowers the self-weight of structures and reduces transportation, erection, and foundation costs. Induction hardening (IH) process which involves rapid heating and cooling of the material leads to microstructural changes which enhance the hardness and strength of conventional steel, elevating it to the level of High Strength (HS) steel. This study reports an extensive investigation on the buckling response and design of IH post-treated structural steel Circular Hollow Sections (CHS). It includes tensile coupon tests, microstructural analyses, initial geometric imperfection measurements, and residual stress evaluations to determine the effects of IH treatment on CHS. Column buckling tests were conducted, and a numerical model was developed and validated against the experimental results which was utilised to study systematically the effect of imperfections. The findings suggest that the magnitude of the imperfections in IH steel sections doubled compared to the non-treated condition, whilst there was a minimal impact on the residual stresses. A comprehensive parametric study was performed using finite element models to study the structural response of IH steel CHS columns over a large range of global slendernesses and allow the assessment of the buckling curves specified in EN 1993–1–1. It was concluded that the buckling curve a (imperfection factor, α=0.21) specified in EN 1993–1–1 provides the best buckling load predictions for the IH steel CHS columns, the response of which is superior to that of their virgin counterparts, despite the increased imperfections caused by the heat-treating process.

Effect of Land Configuration and Vermicompost on Hardening Status of Gaillardia pulchella under Micro-climate Conditions

Gaillardia (Gaillardia pulchella Foug), commonly known as the blanket flower, is a herbaceous perennial renowned for its vibrant, daisy-like flowers. This paper provides a thorough examination of G. pulchella, encompassing its botanical characteristics, hardening configuration, and ecological significance. The present study investigates the impact of land configuration and vermicompost application on the growth metrics of Gaillardia pulchella, and discuss how different configurations affect microclimate conditions and plant acclimatization. By evaluating different land configurations and vermicompost treatments, this research aims to optimize cultivation practices for enhancing the plant’s growth performance, floral quality, and overall yield. The findings provide insights into sustainable agricultural practices for improving the productivity and aesthetic value of G. pulchella. The present results suggest that the flat, ridge and furrow and raised bed configuration, particularly with 75% vermicompost with (33.53, 34.44 and 42.70) is optimal for cultivating Gaillardia flowers. However, minimum plant height was observed under the control plot (24.56, 17.77 and 31.72) cm for all three bed types. The maximum number of leaves count treatment were maximum (83.40, 81.46 and 99.26) with 50% vermicompost under flat, ridge and furrow and raised bed configuration. Number of new shoots per plant at hardening was found maximum (8.66, 9.33 and 9.23) under 50% vermicompost. Moreover, the survival percentage (%) were also found maximum (83.40, 81.46 and 99.26) under 50% vermicompost. It may be concluded that by assessing different land configurations and vermicompost treatments which influences the hardening process characterized by plant acclimatization to environmental stress which ultimate the research aims to enhance the resilience and establishment of G. pulchella in controlled environments.

Temporal evolution of mechanical properties in PDMS: A comparative study of elastic modulus and relaxation time for storage in air and aqueous environment

Polydimethylsiloxane (PDMS) is a soft, biocompatible polymer extensively employed in biomedical research, notable for its tunable mechanical properties achieved through cross-linking. While many studies have assessed the mechanical properties of PDMS utilizing macroscopic and microscopic methods, these analyses are often limited to freshly prepared samples. However, the mechanical properties of PDMS can be expected to change during prolonged exposure to water or air, such as interface polymer chain loosening or surface hardening, which are critical considerations in applications like cell culture platforms or microfluidic devices. This paper presents a comprehensive 10-day investigation of the evolution of PDMS surface mechanical properties through AFM-based nano-indentation. We focused on the most commonly utilized crosslinker-to-base ratios of PDMS, 1:10 (r10) and 1:20 (r20), under conditions of air and deionized water storage. For r10 samples, a hardening process was detected, peaking at 2.12 ± 0.35 MPa within five days for those stored in air and 1.71 ± 0.16 MPa by the third day for those immersed in water. During indentation, the samples displayed multiple contact points, suggesting the formation of distinct regions with varying mechanical properties. In contrast, r20 samples exhibited better stability, with an observed elastic modulus averaging 0.62 ± 0.06 MPa for air-stored and 0.74 ± 0.06 MPa for water-stored samples. Relaxation experiments, interpreted via the General Maxwell Model featuring two distinct component responses, a relatively consistent fast response τ1 (on the order of 10−1 s), and a more variable, slower response τ2 (on the order of 10 s), throughout the study period. The identification of two distinct relaxation times suggests the involvement of two disparate material property regimes in the relaxation process, implying changes in the surface material composition at the interface with air/water. These variations in mechanical properties could significantly influence the long-term functionality of PDMS in various biomedical applications.

Early-age shrinkage behavior of cement mixtures regulated with metakaolin-based internal conditioning

Shrinkage occurs in concrete during its hardening and strength gain process leading to undesired deformation, cracking, and decreases in strength and durability. While metakaolin-based internal conditioning (MIC) has been validated as a promising technique for modifying cement and mitigating alkali-silica reactions in concrete, its impact on the early-age shrinkage behavior of cement remains unexplored. This study delves into the effects of MIC and its coupling with lithium on the chemical shrinkage, autogenous shrinkage, and drying shrinkage of portalnd cement incorporating 30 % metakaolin with varying degrees of saturation (50 %, 75 %, and 100 %). The results indicate that the hydration of cement can be substantially enhanced by MIC with 29.0 % more heat released and a 32.3 % decrease in calcium hydroxide content. As a result of the enhanced hydration, cement with MIC yielded increased chemical shrinkage. Compared with dry MK, the autogenous shrinkage and drying shrinkage of cement were decreased by 38.0 % and 11.0 %, respectively, in the presence of MIC. A synergistic effect between MIC and lithium was suggested by the higher efficacy in suppressing autogenous shrinkage.

On Theoretical Aspect of Photons Emission From Quark-Gluon Interaction Upon Hard Collision

Abstract This work applies a quantum chromodynamics theory QCD to photon emission from heavy quark-gluon scattering in the strong interaction quark-gluon to study and calculate photon flow in hard interaction processes. The photon flow from the dense quark-gluon interaction was calculated using critical temperature, quantum chromodynamic coupling and fugacity at chemical potential μq (500 MeV) for the anti-top with gluon interaction in t ¯ g → s ¯ γ system. The photon flow spectrum in hard collisions is described under the first leading order approximation for QCD theory at finite chemical potential and critical temperature using various photon energy values dependent on the fugacity of quark and gluon. Photon flux calculation provided valuable insights into QGP conditions. The coupling strength αc (T) calculation is a strongly decreasing function of critical temperature ranging 107MeV ≤ Tc ≤ 145MeV and also find appreciable increasing as a result of increasing temperature of system ranging 180MeV ≤ T ≤ 360MeV. The photon flow produced in the t ¯ g → s ¯ γ system was observed in the low range of photon energy with two critical temperatures. The total photon emission strongly decreases marginally as a function of the increase in photon energy. The photon flow emission was found to have appreciable enhancement at the anti-top quark interaction with gluon and it increases highly as a result of the increased temperature of the system and reaches to maximum near 360 MeV at minimum strength coupling in the energy of the photon 1GeV≤E≤2 GeV.

Study of the Martensitic Transformation of Steel During the Induction Hardening Process by means of Acoustic Emissions

Non-Destructive Testing (NDT) technology known as Acoustic Emission (AE) has been used to investigate the phase transformation of 42CrMo4 steel in a cylinder during an induction hardening process. The objective of this study is to characterize the martensitic transformation of the material using the data obtained by the AE sensor during the process. The heating process of the cylinder is carried out statically, focusing the heat on the area to be treated and then analyzing it. After quenching, destructive tests are carried out to determine the hardness and three-dimensional geometry of the steel microstructure after the process (hardness and X-ray diffraction tests). Once the microstructure of the material is known, it is possible to relate the results with the signals obtained by AE, making possible in future induction hardening processes the estimation of martensite by non-destructive techniques.

Comparison of the Properties of Cold Work Tool Steels with the Same Hardness but Different Manufacturing Processes The required important properties

Comparison of the Properties of Cold Work Tool Steels with the Same Hardness but Different Manufacturing Processes The required important properties

ASSESSMENT OF THE INFLUENCE OF INORGANIC PIGMENTS ON THE TECHNOLOGICAL PROPERTIES OF DECORATIVE CEMENTS

The article presents the results of research on the influence of inorganic pigments on the technological properties of decorative cements. It has been established that regardless of the color of the pigment, with an increase in its quantity in the system, we get a more saturated and bright color of cement stone, but at the same time there is a negative effect of pigments and technological and physical and mechanical properties of artificial stone. The research was conducted on cement systems based on white Portland cement without additives and on cement systems based on white Portland cement modified with polycarboxylate superplasticizer. An increase in the amount of pigment, regardless of its color, leads to an increase in the water consumption of the cement system, however, when a superplasticizer is introduced, the effect of the pigment is not so significant. At the same time, the introduction of a superplasticizer reduces the water consumption of white cement without the introduction of pigments by an average of 37-40%. In addition, it was established that the introduction of pigments affects the hardening time of cement systems. At the same time, pigments, depending on their color and dosage, have different effects on both the start and end of aging. With an increase in the pigment content in a cement system without a plasticizer, the time of the onset of hardening increases, and the introduction of a permanent pigment has the greatest effect on the end of hardening of such a system. The introduction of pigments into plasticized cement systems increases both the start and end time of hardening. As the number of pigments of all colors increases, the strength of the samples decreases. At the same time, the red pigment leads to the greatest decline in strength at all stages of hardening. The decrease in strength can be explained by the increased water consumption, and, as a result, the increased porosity of pigmented samples compared to samples without the introduction of pigments. Further research aimed at finding additives that will reduce the negative impact of inorganic pigments on the processes of hydration and hardening of the cement system, and therefore on the durability of the obtained artificial stone, will be relevant. At the same time, it is important to preserve the intensity of the color and the absence of sediment formation.

Design and Technological Aspects of Integrating Multi-Blade Machining and Surface Hardening on a Single Machine Base

Modern mechanical engineering faces high competition in global markets, which requires manufacturers of process equipment to significantly reduce production costs while ensuring high product quality and maximum productivity. Metalworking occupies a significant part of industrial production and consumes a significant share of the world’s energy and natural resources. Improving the technology of manufacturing parts with an emphasis on more efficient use of metalworking machines is necessary to maintain the competitiveness of the domestic machine tool industry. Hybrid metalworking systems based on the principles of multi-purpose integration eliminate the disadvantages of monotechnologies and increase efficiency by reducing time losses and intermediate operations. The purpose of this work is to develop and implement a hybrid machine tool system and an appropriate combined technology for manufacturing machine parts. Theory and methods. Studies of the possible structural composition and layout of hybrid equipment at integration of mechanical and surface-thermal processes were carried out, taking into account the basic provisions of structural synthesis and componentization of metalworking systems. Theoretical studies were carried out using the basic provisions of system analysis, geometric theory of surface formation, design of metalworking machines, methods of finite elements, and mathematical and computer modeling. The mathematical modeling of thermal fields and structural-phase transformations during HEH HFC was carried out in ANSYS (version 19.1) and SYSWELD (version 2010) software packages using numerical methods of solving differential equations of unsteady heat conduction (Fourier equation), carbon diffusion (2nd Fick’s law) and elastic–plastic behavior of the material. The verification of the modeling results was carried out using in situ experiments employing the following: optical and scanning microscopy; and mechanical and X-ray methods of residual stress determination. Formtracer SV-C4500 profilograph profilometer was used in the study for simultaneous measurement of shape deviations and surface roughness. Surface topography was assessed using a Walter UHL VMM 150 V instrumental microscope. The microhardness of the hardened surface layer of the parts was evaluated on a Wolpert Group 402MVD. Results and discussion. The original methodology of structural and kinematic analysis for pre-design studies of hybrid metalworking equipment is presented. Methodological recommendations for the modernization of multi-purpose metal-cutting machine tool are developed, the implementation of which will make it possible to implement high-energy heating with high-frequency currents (HEH HFC) on a standard machine tool system and provide the formation of knowledge-intensive technological equipment with extended functionality. The innovative moment of this work is the development of hybrid metalworking equipment with numerical control and writing a unique postprocessor to it, which allows to realize all functional possibilities of this machine system and the technology of combined processing as a whole. Special tooling and tools providing all the necessary requirements for the process of surface hardening of HEH HFC were designed and manufactured. The conducted complex of works and approbation of the technology of integrated processing in real conditions in comparison with traditional methods of construction of technological process of parts manufacturing allowed to obtain the following results: increase in the productivity of processing by 1.9 times; exclusion of possibility of scrap occurrence at finishing grinding; reduction in auxiliary and preparatory-tasking time; and reduction in inter-operational parts backlogs.