Gear Teeth of Ball Mills: Wear, Restoration, and Mathematical Modeling
Keywords:
electro-slag surfacing, large-module gears, planning of multifactor experiment, crystallizer, roughness, hardness.
Abstract
This study focuses on the restoration of large-module gear teeth of ball mills using the electroslag welding method, with an emphasis on practical results and mathematical modeling. The research established that optimal electroslag welding conditions are achieved by stabilizing key process parameters, such as current strength, slag bath volt-age, and cooling water flow rate. For high-quality welding of gear teeth with a module of 20 mm, the following parameters are recommended: current strength I=362.5 A, slag bath voltage U=73.25–74 V, and water flow rate Qw=3–3.5 l/min. These parameters ensure minimal roughness and the required hardness of the welded teeth. Mathematical modeling provided equations linking welding modes with the roughness and hardness of the welded teeth. The presented experimental data are highly relevant for the scientific com-munity and enterprises involved in the restoration of large-module gear wheels. The results hold significant practical value as they enable enterprises to reduce restoration costs and enhance the durability of components.
References
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2. Y.Huangfu,X.Dong, K.Chen, Zh.Peng. Coupling mechanism between systematic elastic deformation and gear surface damage. International Journal of Mechanical Sciences, Vol. 238, 2023, 107850. https://doi.org/10.1016/j.ijmecsci.2022.107850.
3. J.C. Poletto, C.G. Fernandes, L.Y. Barros, P.D. Neis, K. Pondicherry, D. Fauconnier, O. Seabra, P. De Baets, N.F. Ferreira. Identification of gear wear damage using topography analysis. Wear, Vol.522, 2023, 204837. https://doi.org/10.1016/j.wear.2023.204837.
4. V.G. Sfakiotakis, D.E. Katsareas, N.K. Anifantis. Boundary element analysis of gear teeth fracture. Engineering Analysis with Boundary Elements, Vol. 20, Issue 2, 1997, P.169-175. https://doi.org/10.1016/S0955-7997(97)00062-3.
5. W. Wang, J. Zhao, R. Zhai. A forming technology of spur gear by warm extrusion and the defects control. Journal of Manufacturing Processes. Vol. 21, 2016, pp. 30-38. https://doi.org/10.1016/j.jmapro.2015.10.001.
6. S. Lj, T. Lazovic. Technological heredity – A decisive factor for tribological features of regenerated gears. Engineering Failure Analysis. Vol.42, 2014, pp. 121-132. https://doi.org/10.1016/j.engfailanal.2014.04.004.
7. M. Miladinov, S. Sedmak, B. Djordjevic, A. Sedmak,F.Vucetic, A. Milivojevi. Repairing of cracks on tooth gear ring of a bucket-wheel excavator. Procedia Structural Integrity, Vol. 48, 2023, P. 27-32. https://doi.org/10.1016/j.prostr.2023.07.106.
8. W. Yuqin, Zh. Wei, T Jinyuan. Research on the correlation between roughness parameters and contact stress on tooth surfaces and its dominant characteristics. Measurement, Vol. 238, 2024, 115399. https://doi.org/10.1016/j.measurement.2024.115399.
9. H. Ding, Sh. Rong, X. Zhang, K. Li, K. Rong, Zh. Zhou. Roughness tooth surface loaded contact pressure forecasting model for face-hobbed hypoid gears. Advanced Engineering Informatics, Vol. 60, 2024, 102399. https://doi.org/10.1016/j.aei.2024.102399.
10. W. Yuqin, Zh. Wei,T. Jinyuan. Research on the correlation between roughness parameters and contact stress on tooth surfaces and its dominant characteristics. Measurement, Vol. 238, 2024, 115399. https://doi.org/10.1016/j.measurement. 2024.115399.
11. W. Yuqin, Zh. Wei,T. Jinyuan. Composite effects of residual stress and hardness gradient on contact fatigue performance of rough tooth surfaces and optimization design of detailed characteristic parameters. Engineering Failure Analysis, Vol.162, 2024, 108424. https://doi.org/10.1016/j.engfailanal.2024.108424.
12. GOST 2789-73 (ST SEV 638-77). Surface Roughness. Parameters and Characteristics. Moscow: Standards Publishing, 2024, 10 pp.
13. Method for Measuring Surface Roughness Parameters According to GOST 2789-73. Using Profile Method Instruments MI41-75. Moscow: Standards Publishing, 2015, 15 pp.
14. GOST 9013-59 (ISO 6508-86) Metals. Rockwell Hardness Test Method. Moscow: Standards Publishing, 2001, 10 pp.
15. J.K. Kalita, D.K. Bhattacharyya, S. Roy. 1–Introduction. Fundamentals of Data Science.Theory and Practice. 2024, Pages 1-13. https://doi.org/10.1016/B978-0-32-391778-0.00008-9.
16. D. Huang, F. Wu, Y. Zhao, Jun Yan, H. Zhang. Application of high-credible statistical results calculation scheme based on least squares Quasi-Monte Carlo method in multimodal stochastic problems. Computer Methods in Applied Mechanics and Engineering, Vol. 418, Part B, 5, 2024, 116576. https://doi.org/10.1016/j.cma.2023.116576.
17. Z. Song, A. Mukherjee, P. Qiu, M. Zhou. Two robust multivariate exponentially weighted moving average charts to facilitate distinctive product quality features assessment. Computers & Industrial Engineering, Vol.183, 2023, 109469. https://doi.org/10.1016/j.cie.2023.109469.
18. L. Zhu, Sh. Wang, H. Pan, C. Yuan, X. Chen. Research on remanufacturing strategy for 45 steel gear using H13 steel powder based on laser cladding technology. Journal of Manufacturing Processes, Vol., 2020, pp. 344-354. https://doi.org/10.1016/j.jmapro.2019.12.009.
19. S. Kumar, R. Singh. Investigation of tensile properties of shielded metal arc weldments of AISI 1018 mild steel with preheating process. Materialstoday: proceebings. Vol. 26, Part 2, 2020, pp. 209-222.
