ISSN 1068-798X, Russian Engineering Research, 2009, Vol. 29, No. 1, pp. 71–74. © Allerton Press, Inc., 2009. Original Russian Text © A.G. Boim, R.M. Pratusevich, V.V. Kaminskaya, Z.M. Levina, 2008, published in STIN, 2008, No. 10, pp. 2–5.
D. N. Reshetov and the Design of Metal-Cutting Machines A. G. Boim, R. M. Pratusevich, V. V. Kaminskaya, and Z. M. Levina DOI: 10.3103/S1068798X09010171
time of the parts. The practical introduction of such calculations occurred much earlier in machine-tool design than in other branches of manufacturing.
D. N. Rashetov was born on October 6, 1908, in Tveri. He graduated from Bauman Moscow Technical College (MTC) in 1930, and worked for 57 years in machine-tool design. He worked at the Experimental Scientific-Research Institute of Machine Tools (ESIMT) from the day that it was founded. In this period, Reshetov was involved in solving the basic problems of machine-tool design, including the investigation of drives and their components, machinetool rigidity and dynamics, precision, temperature deformation, the strength and durability of the basic components, and the selection of optimal machine-tool characteristics. His findings were widely used in industry. At the same time, Reshetov taught: until 1953 at MTC (from 1935, in the department of metal-cutting machines, he presented a course on machine-tool design); from 1947 at Moscow Aviation Technical Institute (as head of the department of metal-cutting machines); and from 1953 at MTC (as head of the machine-parts department). In his research, Reshetov addressed the main problems facing machine-tool designers. In machine-tool design, there was a pressing need for adequate design methods and relevant reference materials. To this end, a theoretical-calculation group was formed in the mid-1930s and subsequently became a design laboratory, under Reshetov’s leadership. In this group, Reshetov conducted research and developed design recommendations for spindles and shafts, taking account of their elastic interaction with the bearings. (The results were published in three monographs between 1937 and 1939.) Before World War II, he began to create standard calculations for basic mechanisms and components of machine tools (published in four volumes in 1942 and 1943). In 1945, Reshetov completed his monograph Calculations of Machine-Tool Components, which became the handbook for designers in various branches of manufacturing. This book, written in World War II, was the prototype of his later volume, Machine Parts, which became a key manufacturing textbook for universities. Reshetov converted strength calculations of parts operating in conditions typical of universal machine tools and other machines into durability calculations, taking account of the variable operating conditions and the specified life-
Recalling the work at ESIMT before and during World War II, Rashetov noted the important role played in his development (as a scientist and a machine-tool researcher) by A. A. Zernov, G. M. Gorokhov, E. G. Alekseev, and V. I. Dikushin (who was subsequently elected to the Soviet Academy of Sciences). In the first years after the war, the goal was to significantly raise the technological level of machine tools and to introduce new models, as a part of a broader range. This called for further development of machine-tool design. In 1946, Reshetov earned a doctoral dissertation for work addressing the calculation of machine-tool components on the basis of contact conditions and became director of the laboratory of machine-tool research, whose staff included G. A. Levit, A. S. Lapidus, and Yu. N. Sokolov, as well as several young specialists (graduates of the machine-tool program), including V. V. Kaminskaya, Z. M. Levina, R. M. Pratusevich, and E. I. Rivin. Rashetov directed the work of each of these scientists. Together, their efforts covered the basic machinetool components and mechanisms: drives, supporting systems, and guide systems. Correspondingly, the basic machine-tool characteristics were considered: strength, rigidity, durability, thermal stability, frictional power losses, and dynamic characteristics. The goal was to create engineering calculations that would be useful to designers in specialized and plant-based design bureaus. Laboratory research and tests confirmed the calculations and provided the necessary data. Much attention focused on operational observations and the collection of statistical material. Thus, the laboratory’s work had a practical orientation. With a clear logical approach, Rashetov formulated the problems to be addressed. He had long discussions regarding the best means of solution of these problems with each staff member. His favorite expression was, “Let’s break this down into pieces.” To spend time in his company was an excellent education for his colleagues at the laboratory and, in subsequent years, for many graduate students whom he oversaw. 71
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Reshetov had great authority among machine-tool designers; designers from all the country’s machinetool plants would come to him for assistance. He highly valued these relationships, which, in turn, enriched his practice. Reshetov and his colleagues played an important part in writing the sections on metal-cutting machines in the encyclopedic handbook Manufacturing (edited by V. I. Dikushin, Moscow, 1949, nine volumes). This book is unique in the world for its breadth of material on machine-tool design and has been employed internationally. To permit faster calculations and broader use of such calculations in machine-tool design, Reshetov led a team that developed (in 1952 and 1953) tabular calculations of drive components, analogous to the calculation of roller bearings. As part of the modernization of Soviet machine tools, Reshetov and his collaborators (V. V. Kaminskaya, Z. M. Levina, and L. B. Kotlyarenko) published the book Calculations in Machine-Tool Modernization (1956), containing simplified tabular calculations and calculations based on similarity. The introduction of high-speed cutting using hardalloy tools resulted in enormous energy losses in existing machine tools. The creation of new high-speed machine tools called for extensive research on frictional losses in mechanisms. As a result, the laboratory developed the means of calculating the losses of mechanisms when idling and under load (G. A. Levit). On that basis, design errors could be avoided, and recommendations for reducing losses in high-speed machinetool drives could be formulated. In response to the development of heavy-duty machine tools, requirements on the precision of machine tools under load, and the need to reduce metal consumption, there was a demand for calculations of the supporting systems in machine tools. In the laboratory, extensive research was undertaken on the rigidity of supporting systems and guide systems, culminating in the monograph Machine-Tool Frames and Housings by V. V. Kaminskaya, Z. M. Levina, and D. N. Reshetov (1960). The rigidity of standard structural elements in supporting systems under standard loads was studied theoretically (on the basis of structural mechanics) and experimentally. This permitted significant simplification of the calculations and the development of recommendations regarding optimal structures, which were adopted in design practice. Subsequently, Kaminskaya studied the operation of supporting systems in combination with the base plate (including research on heavy-duty and high-precision machine tools). Methods of supporting-system calculation were proposed for pulsed vibrations (in particular, when reciprocating machine-tool components reverse) and for random vibrations originating in the base. The results were published in the book Foundations and
Installation of Metal-Cutting Machines by V. V. Kaminskaya and D. N. Reshetov (1975) and in Soviet standards. In the 1960s, the laboratory developed designs for vibrationally insulating rubber–metal supports for machine-tool installation without a foundation, and their mass production was organized. Antivibration devices with elastically damping elements (such as couplings and dampers) were also developed and investigated (by E. I. Rivin). The development of precision machine tools demanded calculations of contact temperature deformations. In machine tools, contact deformation plays a significant role in the overall balance of elastic displacements. Investigation of contact deformation for different joints permitted the development of contactrigidity calculations for machine tools and the solution of numerous previously unsolvable problems. This research led to the monograph Contact Rigidity of Machines by Z. M. Levina and D. N. Reshetov (1971). The research on temperature fields and deformation in machine tools begun by Reshetov (with V. E. Smirnov) in the 1940s (specifically for blanks) was continued under his leadership (for housing parts, frames, bearings, shafts, and guide screws) by Yu. N. Sokolov, who developed calculations on the basis of heat-transfer theory. In the 1980s, A. P. Segida developed the automated calculation of temperature fields and temperature strains by the finite-element method, which offered the designer means of evaluating and selecting structures that reduce the temperature and temperature strain. One important strand of the laboratory’s work was to increase the life of components, mechanisms, and machine tools as a whole and to develop corresponding strength calculations. To this end, and also to select optimal characteristics of the machine tools, the distribution of smoothly varying working loads of machine tools in different branches of industry was studied (by R. M. Pratusevich), and dynamic overloads in machinetool drives in transient processes without cutting (starting, braking, etc.) and in discontinuous cutting were investigated (by E. I. Rivin). Their results significantly refined calculations of machine-tool components in terms of selecting the design loads and taking account of the variability of the operating conditions. In addition, they permitted the development of loading programs for strength, endurance, and wear tests of machine-tool components and provided the basis for recommendations regarding the operational characteristics of the primary drive. Subsequent research (by R. M. Pratusevich and A. S. Litvak) addressed the strength of machine-tool components under sudden overloads and in circumstances where brief overloads are superimposed on cyclic loads, which is common in many machines.
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In operational observations and tests of drives (with systematic fracture of gear teeth in the primary machinetool drive), experiments on the strength and durability of gears and other key machine-tool components after various kinds of hardening were conducted over a number of years. The results gave rise to recommendations regarding the rational choice of steels and hardening methods; permitted the refinement of the standard method of gear calculation in the machine-tool industry and the development of a specific calculation method for the few-cycle strength under the action of dynamic loads; and made a significant contribution to the development of State Standard GOST 21354 (the 1975 and 1987 editions) for strength calculations of cylindrical gears (research by D. N. Reshetov, R. M. Pratusevich, and A. S. Litvak). Since the precision and vibrational stability of machine tools are largely determined by the spindles, work on the optimization and calculation of spindles on high-speed roller bearings was undertaken (by A. M. Figatner and others). Fundamental aspects of the operation and calculation of hydrodynamic spindle bearings were considered (including temperature calculation of multiwedge bearings); principles were developed for the design and calculation of hydrostatic bearings for high-precision spindles (by Yu. N. Sokolov and L. N. Tseitlin). Reshetov paid particular attention to the calculation, design, and optimization of machine-tool guide systems. For slipping and rolling guide systems, methods of contact-stress calculation were developed and the guide systems were optimized in terms of rigidity (by D. N. Reshetov and Z. M. Levina). Research (by A. S. Lapidus and B. G. Lur’e) on the wear and scratching of slipping guide systems, optimal materials and protective devices, and antisticking lubricant significantly increased the life of guide pieces and ensured smoothness of slow displacements. Research by G. A. Levit, I. N. Churin, and others focused on the design of hydrostatic guide pieces in heavy-duty, high-precision, and one-of-a-kind machine tools. Reshetov also worked on the development of test methods for machine-tool components and mechanisms. He developed widely adopted approaches to tests of parts, accelerated tests of mechanisms, operational observations, and gearbox tests. The laboratory’s theoretical and experimental findings were published, under Reshetov’s direction, in the two-volume compendium Components and Mechanisms of Metal-Cutting Machines (1972). The book covered basic design principles; operational and dynamic loads; the calculation and design of frames, guide systems, housing components, and precisemotion mechanisms; means of extending the life of general-purpose components; and antivibrational equipment. RUSSIAN ENGINEERING RESEARCH
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The introduction of numerically controlled machine tools in small-scale and series production called for the development of designs for new parts and mechanisms. Work was undertaken on roller guide systems based on roller bearings and combined rolling–slipping guide systems using modern antiskid plastics (research by Z. M. Levina and A. G. Boim). Calculation methods and recommendations regarding the design of such guide systems were developed and tested. Such bearings were put into mass production. On the basis of research at ESIMT and elsewhere, Reshetov and V. T. Portman published the monograph Precision of Metal-Cutting Machines (1986), which demonstrated the influence of precision on the operation of machine-tool components and provided methods for calculating the precision of machine tools and recommendations for increasing it. At the end of his time at ESIMT, Reshetov oversaw the development of automated calculation of parts for general-purpose manufacturing systems and automated design subsystems for mechanisms and machine tools, taking account of comprehensive quality characteristics (research by Z. M. Levina, R. M. Pratusevich, V. V. Kaminskaya, A. G. Boim, A. S. Litvak, and others). Reshetov’s influence is evident in the chapters written by his students for the encyclopedia Manufacturing (1999). Reshetov’s work is characterized by the analysis of the basic laws of the processes under study. This accounts for the relative simplicity of the calculation methods he developed and the possibility of formalizing his results as specific recommendations. It also explains the high scientific level of the dissertations written under his guidance. In his relations with colleagues, students, and researchers from other organizations, Reshetov was genial, patient, and sensitive. He was a careful listener and never raised his voice, but made great demands on himself and his subordinates in pursuit of solutions. His courteous behavior did not temper his zeal in examining fundamental problems. He did not make compromises or consider what was best for his career. Reshetov was a very organized human being. He was the director of laboratories at ESIMT and MTC and also director of the Higher Certification Commission, while at the same time working on books and articles, editing handbooks and encyclopedias, presenting papers at conferences, and participating in the development of GOST and COMECON standards on strength calculations for machine parts. Until the end of his life, he remained vigorous and in good physical shape, thanks to a well-designed regimen of exercise and sports. For example, while working at ESIMT for many decades, he would walk in the courtyard of the Institute during his half-hour lunch break, in any weather and at 2009
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any time of year. He was a tennis player and a swimmer and even wrote and published small brochure with recommendations for beginners in these activities. He gladly took part in holiday celebrations and dinners of the laboratory and department staff. He had a lively sense of humor and was a good storyteller. Under Reshetov’s direction, more than 60 dissertations in machine-tool design at the candidate-of-science and doctoral levels were successfully defended.
His work is known in many countries, and his students are active in Russia and abroad, developing and enriching the scientific school that he founded. The author of this article was privileged to work for many years with Reshetov, a truly remarkable human being. He died on October 12, 2000. Our feelings for Reshetov were best expressed by the great Russian poet Zhukovskii: “Do not be sad: they are no more, but we are grateful that they were.”
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