DOI: https://doi.org/10.30837/2522-9818.2018.3.059

OPTIMIZING THE TECHNOLOGY OF RECONDITIONING LARGE HIGH PRECISION GEAR RIMS

Victor Shapovalov, Alexander Klochko, Magomedemin Gasanov, Olesya Antsyferova, Аnna Belovol

Abstract


The subject matter of the research is issues related to the optimization of the technology for reconditioning large-size high precision gear rims of the drives of mining complexes, mine lifting equipment, heavy vehicles; these issues are a perspective trend for reducing the cost of reconditioning and operation of expensive unique equipment. The goal is to ensure intensifying production processes, increasing workloads and speeds, reducing the deterioration of high precision gear rims. The objective is to develop a new technology to optimize reconditioning large high precision gear rims. To achieve this, the following method is suggested – to machine gear rims after they have been surfaced by pre-milling with special hob cutters with a prominence and by final machining the teeth with special cutters equipped with hardmetal inserts that process teeth along the line of engagement, which does not require making full-length cutting teeth and increases the quality of machining, the durability of hardmetal milling cutters. The process of reconditioning of large high precision gear rims is a resource-saving technology, as compared with manufacturing new parts, this technology considerably reduces the cost of materials for manufacturing, decreases a number of process steps, reduces the cost of machining equipment, tools, cutting and measuring instruments. The smooth operation of a gear train can be ensured only at a constant gear ratio but due to manufacturing and operational errors, the gear ratio is not constant at every time, which intensify the deterioration of large high precision gear rims. The following results are obtained. The possibility and practicability of using hob cutters with a prominence (m = 20-28 mm) while rough cutting the worn and reconditioned large gear rims was proved. To obtain the necessary durability of rough milling cutters, it is recommended that the prominence angle be set within 8-10°. The use of hardmetal hob cutters for finishing makes it possible to increase the performance rate by 2 to 3 times as compared to high-speed cutters of other designs and to obtain the necessary quality and precision of manufacturing worn and reconditioned large gear rims. Conclusions. The technology for the optimization of reconditioning large high precision gear rims with the use of special and universal hardmetal single- and double-flute cutters that have both re-sharpened cutting elements and disposable rotary tools was developed and introduced.

Keywords


new optimization technology; reconditioning large gear rims; high precision; hob cutters with a protuberance; special cutters; machining tooth along the line of engagement; improving the quality of machining

Full Text:

PDF

References


Klochko; A.; Shelkovoy; A.; Shapovalov; V.; Belovol; A.; Antsyferova; O. (2017). Technology of repair and restoration of large-modular hardened gears by high-speed blade processing. Innovative Technologies and Scientific Solutions for Industries. No. 2 (2). P. 38–47. DOI: 10.30837/2522-9818.2017.2.038

Kovalev; V.; Shelkovoy; A.; Klochko; A. (2017). "Technological solutions of the stationary task of working liquids for increasing the durability of gear wheels of the main drives of heavy turning machines"; Innovative Technologies and Scientific Solutions for Industries. No. 1 (1). P. 36–45. DOI: 10.30837/2522-9818.2017.1.036

Belovol; A.; Klochko; A.; Naboka; E.; Skorkin; A.; edited by A. Shelkovoy (2016); Imitation modeling in problems of machine-building production in 2 volumes; T. 1: study; Allowance Kharkiv NTU "KhPI"; 400 p.

Shelkovoy; A.; Klochko; A.; Hasanov; M. (2017); "Maintenance of operational properties of hardened gears"; Bulletin of modern technologies: Sat. scientific tr Sevastopol: FSUE "Sevastopol State University"; Issue 8; P. 61–70.

Shelkovoy; A.; Permyakov; A.; Novikov; F.; Voloshin; A.; Klochko; A.; Hasanov; M. (2017); "Actuality of differentiated and integrated forecasting in conditions of simulation of technological support of operational properties of surfaces of large-sized gear wheels"; Physical and computer technologies. Proceedings of the 23rd International Scientific and Practical Conference. December 21-22; 2017; Kharkov. Odessa: ONPU; P. 36–41.

Permyakov; A; Shelkovoy; A.; Klochko; A.; Okhrimenko; A. (2017); «Modern technologies of increasing durability of cylindrical gears». XVII International Scientific and Technical Conference "Progressive Technology; Technology and Engineering Education"; which took place June 29-July 01; 2017; at the National Technical University of Ukraine "Igor Sikorsky Kiev Polytechnic Institute". Kyiv: NTUU "KPI". T. 4. Р. 348–350.

Starzhinsky; V.; Soliterman; Yu.; Tesker; E.; Goman; A.; Osipenko; S. (2008); "Types of damage to gears: typology and recommendations for the prevention of damage"; Friction and wear; Gomel; T. 29; No. 5; Р. 465–482.

Mironenko; E.; Shapovalov; V.; Klochko; A.; Palashek; S.; Ostapovich; E. (2015); "Design and technological methods of increasing the productivity and quality of the tooth processing of large-sized gears. Bulletin of the NTU "KhPI"; Series: Technology in Mechanical Engineering; Kh.: NTU "KhPI"; No. 4 (1113); P. 28–32.

Timofeev; Yu.; Shapovalov; V.; Klochko; A. and others. (2011); Special technologies of zebot machining of large-modular hardened wheels: monograph; Kramatorsk: DGMA; 128 p.

Timofeev; Yu.; Kane; Yu.; Klochko; A. Shapovalov; V. and others (2014); Technological bases of a toothprocessing of hardened large-modular gear wheels: a monograph; Kramatorsk; DHSA. 479 p.

Mironenko; E.; Klochko; A.; Shapovalov; V.; Chmyrov; V. (2013); "Perfection of the technology of a toothbrush by worm modular cutters with contact-reactive soldering of cutting plates"; Reliability of the tool and optimization of technological systems: ser. scientific tr Kramatorsk: DGMA; Issue 33; P. 3–7.

Suslov; A.; Klochko; A. (2016); "General principles of modeling of optimal control of parameters of accuracy; quality and productivity of tooth processing of hardened large-modular gears"; Problems of designing and automation in mechanical engineering; Collection of scientific works; Scientific and Production Cooperative "Oniks"; Irbit: NPK ONIS; P. 105–119.


GOST Style Citations






Copyright (c) 2018

Creative Commons License
This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License.

All the articles published in ITSSI journal are licensed under CC BY-NC-SA 4.0