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2021 №06 (06) DOI of Article
2021 №06 (01)

Automatic Welding 2021 #06
Avtomaticheskaya Svarka (Automatic Welding), #6, 2021, pp. 44-50

Restoration of worn helical coarse pitch gears by electroslag cladding

S.M. Kozulin1, I.I. Lychko1, S.S. Kovalchuk1, G.S. Podyma2, M.V. Lazarchuk2
1ІЕЗ ім. Є.О. Патона НАН України, 03150, м. Київ, вул. Казимира Малевича, 11. E-mail: office@paton.kiev.ua
2NTUU «Igor Sikorsky Kyiv Polytechnic Institute», 6/2 Dashavska Str., 03506, Kyiv, Ukraine. E-mail: meganom8@ukr.net

The paper presents the results of experimental studies performed with the aim of development of a high-efficient technology, equipment and special technological fixtures for restoration of worn teeth of coarse pitch helical gears by electroslag cladding (ESC). The main objectives of the work were development of the design and method of fabrication of a special water-cooled forming fixture, establishing ESC modes that guarantee fusion of the filler with the base metal, as well as sound formation of the working surfaces of clad teeth; adaptation of the assemblies of batch-produced machine A-535 UKhL4 with TShS 100-3 power source to perform consumable-nozzle ESC by 3 mm electrode wire, using AN-8 and AN-9U fused fluxes; restoration of a test-standard helical gear and assessment of its serviceability. The level of specific heat input that ensures sound teeth restoration was established; welding consumables were selected to ensure the required chemical composition and performance of the deposited metal. A special shop section was set up at repair-mechanical plant of TPA «Bratsk TIC» for restoration of the teeth of coarse pitch gears, where a gear was restored using ESC and sent for performance tests. Operation experience showed that the restored gear has good running smoothness and teeth resistance under the conditions of alternating and contact loads, arising at operation of the debarking drum. Teeth wear on the level of the generating circle is not more than 3 – 5 mm. 10 Ref, 1 Tabl., 8 Fig.
Keywords: restoration, helical gears, coarse pitch, wear, electroslag cladding, consumable nozzle, specific heat input, forming fixture, cladding machine, heat treatment, residual deformations, performance tests

Received: 13.04.2021


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