Ukrainian Journal of Mechanical Engineering and Materials Science

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Author: search.filters.author.Zinko, Yaroslav

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    Technological features of restoration of rims of support rollers for tracked vehicles
    (Видавництво Львівської політехніки, 2023-02-28) Dzyubyk, Andrij; Dzyubyk, Liudmyla; Zinko, Yaroslav; Dzhaliuk, Oleh; Lviv Polytechnic National University
    The use of tracked (caterpillar) vehicles enables us to meet the requirements concerning harmless impact upon the environment, the considerable amounts of work to be fulfilled being saved. In particular, as compared to wheeled vehicles, there is less pressure upon the ground; there is also the opportunity to work in specific conditions of marshy, sandy, and low-bearing soils; stable performance in hard climatic conditions, etc. is also possible there. A necessary and important part of the tracked vehicle is its special suspension. Such a suspension contributes to smoother motion of the mechanism, it also cushions shocks, and ensures transmission of motion from the engine to the tracks. Independently of the design of the suspension, there are always several couples of support rollers. These rollers make up the intermediate link between the mover and the carrier frame, they transmit not only great weight but also the created loading, they guide the tractor’s caterpillars, etc. In the course of their work, the support rollers of tracked vehicles experience intensive wear and tear of the outer surface of their rims. As a result, changing them is necessary; dismounted ones are to be repaired. The use of restorative technology through overlaying (building up) by means of the electric arc is considered in this paper. This enables us to ensure cost savings and to repair support rollers of hardly loaded track vehicles. It is also possible to increase their serviceability by optimizing the overlayed metal; in particular, by increasing the hardness of the overlayed layer and increasing its resistance against impact and abrasive wear. The weldability of the main metal of a support roller has been analyzed. It is shown that the use of high-carbon material complicates the conditions for overlaying the outer rim. It is necessary to use pre-heating to high temperatures. This reduces the tendency of the material to form hardening structures and cracks after the overlaying. Investigations of peculiarities of overlaying a cylindrical surface of the rim of a tractor’s roller have been conducted. In particular, the limit values of the length of a weld pool depending on the diameter (value of wear) of the overlayed rim of a roller have been determined. It is shown that it is necessary to carry out the displacement of the arc from the zenith. This ensures the necessary formation of the weld-pool and the absence of spreading of the metal overlayed on the rim. The determination of the value of heat input of overlaying a roller has been carried out, the heat input is considered as a function of parameters of the electrode wire. Verification calculation of the obtained values of specific power for the permissible length of the weld-pool has been conducted. Concretization of the obtained results was carried out by taking into account the optimal range and permissible rate of cooling in overlaying the main material of a support roller. According to special nomograms, the dependence between the rate of cooling and the heat input of overlaying has been established. Especially, there were investigated the temperature conditions during overlaying the weld beads. It is shown that heating the roller takes place at the expense of neighboring weld beads. It is established that in overlaying at the determined values of heat input (per unit length) there can be achieved the temperature of auto heating is sufficient for the pre-heating of a roller.
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    Optimization of conditions of electroslag welding of bandings of rotary units
    (Publishing House of Lviv Polytechnic National University, 2016) Dzyubyk, Andrii; Dzyubyk, Liudmyla; Zinko, Yaroslav; Biruk, Stanislav
    The design of banding shells of rotary units is analyzed. It is shown that combined welding and cast manufacturing of bandings is used in the case of large structural sizes. The basic materials (30, 35, 25 HSL and 30 HML), being used in this process, are characterized by the tendency of forming of hardening structures due to the thermal cycle of welding. As a result of this, the cracks in the heat-effected zone, which lead to the destruction of the connection under the influence of welding residual stresses. The analysis of literature sources has shown that the usage of electroslag welding is perspective during the manufacturing and welding of operational cracks. Thus it is important to define the correct parameters of the welding conditions. In the case of electroslag method they are different from the arc methods and are characterized by the larger amount. In the paper the technological process of welding of banding (tread) ring with the external diameter of 4600 mm, wall thickness of 300 mm and wideness of 500 mm, which is made of steel 35. The defining of regime parameters is made using the following recommended techniques: taking into account the chemical composition of the basic metal; according to the nomogram depending on the ratio of the thickness of the metal to the number of electrode wires; using the calculation (design) method according to the conditions of electroslag welding of the banding. Taking into account the tendency of the steel 35 to cracks forming (cracking), the evaluation of the structure and phase composition and mechanical properties of metal of heat-effected zone of the weld. In order to define the microstructure, the cooling rate of the metal in the range of structural transformations was determined and the diagram of anisothermal decomposition of austenite was used. The technique of determination of the metal cooling rate as a result of the influence of thermal cycle of electroslag welding is proposed in the paper. It is based on the usage of special nomograms which characterize the specific features of the process being studied. The cooling rate equals w= 0.1876 degrees per second when using the developed process parameters. Also the investigation of temperature distribution in the cross-section of the weld has been carried out. It is shown that there are no significant deviations of temperature when using the proposed regime parameters. This influences the reduction of the level of residual stresses along the thickness of the weld. The analysis of the diagram of austenite transformation has shown that the structure of the steel 35 in the initial state is ferrite one with the mixture of pearlite and bainite. As a result of welding carrying out the structure will have a similar composition with slightly larger content of perlite and bainite. It was defined that their content in the heat-effected zone is as follows: 39 % for ferrite, 61 % for the mixture of perlite and bainite. At the same time, the investigated technology of electroslag process ensures the slow heating and cooling of the areas around the weld and obtaining of satisfactory mechanical properties of the metal. Therefore, the combined usage of existent techniques of regime parameters determination is expedient. Also it is necessary to carry out the verification of physical and chemical properties of the metal of heat-effected zone in order to prevent the formation of hardening structures.