Automatic Welding, 2025, №05

2025 №05 (08)

DOI of Article 10.37434/as2025.05.09

2025 №05 (01)

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"Avtomatychne Zvaryuvannya" (Automatic Welding), #5, 2024, pp. 75-80

Restoration of worn gears of a quarry excavator by electroslag surfacing

S.M. Kozulin¹, A.A. Fomakin¹, R.N. Mishchenko¹, L.M. Petrenko²

¹E.O. Paton Electric Welding Institute of the NAS of Ukraine 11 Kazymyr Malevych Str., 03150, Kyiv, Ukraine. E-mail: s.m.kozulin@gmail.com
²Admiral Makarov National University of Shipbuilding. 9 Heroes of Ukraine Ave., 54007, Mykolayiv, Ukraine. E-mail: university@nuos.edu.ua

The results of experimental research carried out with the aim of developing a high-performance technology, equipment and special technological fixtures for restoring the pitch profile of worn teeth of the drive gears of the rotary platform of MARION 204-M «Super Front» quarry excavators by electroslag surfacing (ESS) are presented. A design of special water-cooled forming equipment was developed that eliminates the need for machining the working profiles of the teeth after their surfacing. A laboratory surfacing installation was designed and manufactured. A search for ESS modes was performed that provide guaranteed fusion of the filler metal with the base, as well as high-quality formation of the working surfaces of the surfaced teeth; restoration by ESS of worn teeth of experimental and standard gears; assessment of the operability of the restored gears according to the results of operational tests. Working drawings of an experimental and industrial specialized installation for restoring worn teeth of drive gears and gearwheels were developed. To implement the technology of restoration repair, a serial A-535 UHL4 system with an alternating current TShS 1000-3 power source was used. The material from which the drive gears of the excavator platform gearboxes are made is high-strength structural steel JIS SCM4. Serial welding wires of Sv 30KhGSA grade and AN-8 fused flux were used as welding materials. The experience of operational tests has shown that the restored gears have good smoothness and stability of the teeth during operation in the reverse mode under the conditions of significant alternating and contact loads. The wear of the teeth at the level of the generatrix does not exceed 1.5...3 mm. Working drawings of the experimental and industrial UD 484 UHL4 installation for the restoration of worn teeth of gears and gear wheels using ESS have been developed. 9 Ref., 2 Tabl., 8 Fig.
Keywords: restoration, gears, tooth pitch profile, wear, electroslag surfacing, consumable nozzle, forming equipment, fusion quality, surfacing installation, heat treatment, operational testing


Received: 06.05.2025
Received in revised form: 16.06.2025
Accepted: 07.10.2025

References

1. Petrov, I.V. (1990) Current repairs and maintenance of construction machines. Kyiv, Transport [in Ukrainian].
2. Bubnovskiy, B.I., Efimov, V.N., Morozov, V.I. (1991) Repair of walking excavators. In: Refer. Book. Moscow, Nedra [in Russian].
3. (1980) Excavator 204-M «Super Front». Operating instructions Sumitomo Marion Corporation, Japan-USA.
4. Sushchuk-Slyusarenko, I.I., Lychko, I.I., Kozulin, M.G., Semenov, V.M. (1989) Electroslag welding and surfacing in repair work. Kyiv, Naukova Dumka [in Russian].
5. Artamonov, V.L., Sushchuk-Slyusarenko, I.I. (1988) Electroslag surfacing (Review). Avtomaticheskaya Svarka, 11, 41- 47 [in Russian].
6. Kuskov, Y.M, Ryabtsev, I.O. (2022) Electroslag surfacing. Materials, technologies, equipment. Monograph. Ed. by I.O. Ryabtsev. Kyiv, Interservice [in Ukrainian]. https://doi.org/10.1007/978-3-031-34390-2_4
7. Kozulin, S.M., Podyma, G.S. (2021) Device for restoring involute profiles of teeth of large-module gears. In: Reports of the Xth All-Ukrainian Sci. and Pract. Conf. of Students, Postgraduates and Young Scientists on Applied Geometry, Design, Intellectual Property Objects and Innovative Activities of Students and Young Scientists», Issue 10, Kyiv, DIYA, 16-21 [in Russian].
8. Kozulin, S.M., Sushchuk-Slyusarenko, I.I., Lychko, I.I. (2006) Effect of ESC parameters on quality of restored gear teeth. The Paton Welding J., 9, 47-49.
9. Kozulin, S.M., Lychko, I.I., Kovalchuk, S.S., Podyma, G.S., Lazarchuk, M.V. (2021) Restoration of worn helical coarse pitch gears by electroslag cladding. The Paton Welding J., 6, 41-47. https://doi.org/10.37434/tpwj2021.06.07

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