DOI: https://doi.org/10.32515/2414-3820.2024.54.3-11
Prospects of Modern Methods of Butt Welding for the Manufacture of Blanks and Repair of Crankshafts
About the Authors
Viktor Oshovskyі, Associate Professor, PhD in Technics (Candidate of Technics Sciences), Pervomaisky Educational and Research Institute of Admiral Makarov National University of Shipbuilding, Pervomaysk, Ukraine, e-mail: oshovskyvikt@ukr.net, ORCID ID: 0000-0002-8065-907X
Igor Kapura, PhD in Technics (Candidate of Technics Sciences), Senior lecturer, Pervomaisky Educational and Research Institute of Admiral Makarov National University of Shipbuilding, Pervomaysk, Ukraine, ORCID ID: 0009-0008-1695-389X
Oleksandr Shostak, Senior lecturer, Pervomaisky Educational and Research Institute of Admiral Makarov National University of Shipbuilding, Pervomaysk, Ukraine, ORCID ID: 0000-0003-4461-1009
Abstract
The purpose of the study is to analyze modern productive automated methods of electrostatic welding that are promising for technologies for manufacturing blanks or repairing steel crankshafts from prefabricated parts to replace stamping, forging, and other unproductive methods, as well as to increase material utilization, quality, reliability, and the possibility of implementing these methods at engine-building enterprises.
It is noted that the existing stamping methods cause shape deviations when the crankshafts are twisted. And when forging large shafts, due to the need to simplify the workpiece, adjacent jowls and connecting rods are combined with large overlaps, which contribute to a very low material utilization rate, a decrease in reliability due to fiber cutting when they are cut. In addition, there are shape errors in the heat treatment process of crankshafts - bending of the workpiece, which is a very time-consuming and costly operation, “turning the crank arm over” during the settling process, which is determined as the main defect in the shaft shape. The manufacture of large shafts requires specialized enterprises with unique pressing equipment and highly qualified workers. It is proposed to manufacture crankshafts from prefabricated journals with half journals, or journals and journals by modern methods of electrostatic welding, automated by computer control - small shafts with pulsating melting; and large shafts with melting by a controlled arc rotating in an Archimedean spiral under the action of a radial magnetic field of solenoids. To increase efficiency, it is proposed to further enhance the magnetic induction of the field with neodymium magnets.
The proposed methods of manufacturing and repairing crankshafts will increase the material utilization rate to the maximum, reduce shaft shape errors by eliminating heat treatment after manufacturing or repair, obtain high quality and reliability of shafts, and automate the manufacturing process.
Keywords
crankshaft, journals, jowls, forging, resistance welding, rotating arc welding
Full Text:
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References
1. Dobrianskyi, S.S., Malafeev Yu.M., & Puhovskyi, Ye.S. (2014). Design and production of blanks: a textbook. Kyiv: NTUU «KPI» [in Ukrainian].
2. Klemeshev, Ye.S. (2018). Development of theoretical and technological foundations of the metal-saving process of forging connecting rod journals of large crankshafts. Thesis for the degree of candidate of technical sciences. Dnipro: National Metallurgical Academy of Ukraine [in Ukrainian].
3. Milenin, A., Rec, T., Walczyk, W., & Pietrzyk M. (2014). Model of curvature of crankshaft blank during the heat treatment after forging. Procedia Engineering, 81, 498-503 [in Poland].
4. Miao, J., Shiyan, Z, Baofeng, G., & Qun L. (2010) Study on bending and upsetting forging 305 marine crankshafts. Advanced Materials Research, 101, 337 – 343 [in Switzerland]. DOI : 10.4028/www.scientific.net/AMR.97-101.337
5. Sologyb, M.A., Rozhnetskyi, O.I., Nekoz, O.I., Gorpenyuk M.A., & Preys G.O. (2002). Technology of structural materials: a textbook. M.А. Sologyb (Ed). Kyiv: Vycha Shkola [in Ukrainian].
6. Beloev, M., Khomenko, V.I., & Kuchuk-Yatsenko S.I. (2013) Selection of welding technologies in construction of large-diameter main pipelines. The Paton Welding Journal, 10/11, 131-134 [in Ukrainian].
7. Kuchuk-Yatsenko, S.I., Shvets, V.I., Didkovsky, A.V., Antipin, E.V., & Kapitanchuk, L.M. (2013) Defects of joints of high-strength rails produced using flash-butt welding. The Paton Welding Journal, 9, 2-8 [in Ukrainian].
8. Kuchuk-Yatsenko, S.I., Rudenko, P.M., Didkovsky, A.V., & Antipin, Ye.V. (2021) Operational control of the process of resistance butt welding of railway rails using the pulsed arc method. The Paton Welding Journal, 5, 8-14 [in Ukrainian].
9. The method of resistance butt welding: Patent 46820 Україна : МПК В23К 11/04 (2006.01). (22) : 28.07.1998; (46) : 17.06.2002. Bulletin 6.
10. Ukrainian Railways received the first rail welding machines on the Volvo Trucks platform. Rail.insider. 04.06.2020 URL : https://www.railinsider.com.ua/ukrzaliznyczya-otrymala-pershi-rejkozvaryuvalni-mashyny-na-platformi-volvo-trucks/ .
11. Method of press welding with a magnetic field controlled arc : patent 46036 Україна, МПК В23К 9/08 (2006.01); (22) : 21.01.1998; (46) : 15.05.2002. Bulletin 5.
12. Kachinsky, V.S., & Kuchuk-Yatsenko, S.I. (2017) Joint formation in magnetically-impelled arc butt welding of thick-walled pipes from high-strength steels. The Paton Welding Journal, 8, 39-45 [in Ukrainian].
13. Kachinsky, V.S., Kuchuk-Yatsenko, S.I., & Koval, М.P. (2020) Press welding of high-strength steel tubular parts of hydraulic cylinders with magnetically controlled arc. The Paton Welding Journal, 1, 45-50 [in Ukrainian].
14. Kuchuk-Yatsenko, S.I., Kachunskyi, V.S., & Koval, M.P. (2020). Development of technology and equipment for press welding of tubular parts in production conditions to save resources and improve the reliability of highly loaded products. Paton Welding Journal, 10, 3-7 [in Ukrainian].
15. Chen, Haidong, MA, Tiejun, ZHANG, Yong, & ZHANG, Xiaoyu. (2012) Microstructural analysis of mild steel joint by flash butt welding with external magnetic field[J]. Transactions of the China welding institution, 2, 109-112 [in China].
16. Krivtcun, I.V., Kvasnytckyi, V.V., Maksymov, C.Yu., & Yermolayev, G.V. (2017). Special welding methods: a textbook. B.Ye. Paton (Ed). Mykolayiv: NUK [in Ukrainian].
Citations
1. Добрянський С.С., Малафєєв Ю.М., Пуховський Є.С. Проектування і виробництво заготовок / підручник. К. : НТУУ «КПІ», 2014. 353 с.
2. Клемешов Є.С. Розвиток теоретичних та технологічних основ металозаощаджувального процесу кування шатунної шийки великогабаритних колінчастих валів : дис. вч. cтупеня канд. техн. наук : 05.03.05. Дніпро : Нац. металург. акад. Укр., 2018. 158 с.
3. Milenin A., Rec T., Walczyk W., Pietrzyk M. Model of curvature of crankshaft blank during the heat treatment after forging. Procedia Engineering, AGH Krakow. 2014. Vol. 81. P. 498-503.
4. Miao, J. Z., Shiyan, G., Baofeng, L. Qun.Study on bending and upsetting forging 305 marine crankshafts. Advanced Materials Research, Switzerland. 2010. № 101. P. 337-343. DOI : 10.4028/www.scientific.net/AMR.97-101.337
5. Технологія конструкційних матеріалів : підручник. Вид. 2-ге, переробл. і допов. / М.А. Сологуб, І.А. Рожнецький, О.І. Некоз та ін.; за ред. М.А. Сологуба. К. : Вища шк., 2002. 374 с.
6. Beloev M., Khomenko V.I., Kuchuk-Yatsenko S.I. Selection of welding technologies in construction of large-diameter main pipelines. The Paton Welding Journal. 2013. № 10/11. Р. 131-134.
7. Kuchuk-Yatsenko S.I., Shvets V.I., Didkovsky A.V., Antipin E.V. Kapitanchuk, L.M. Defects of joints of high-strength rails produced using flash-butt welding. The Paton Welding Journal. 2013. № 9. P. 2-8.
8. Кучук-Яценко С.І., Руденко П.М., Дідковський О.В., Антіпін Є.В. Операційний контроль процесу контактного стикового зварювання залізничних рейок методом пульсуючого оплавлення. The Paton Welding Journal. 2021. № 5. С. 8-14.
9. Спосіб контактного стикового зварювання оплавленням : пат. 46820 Україна : МПК В23К 11/04 (2006.01) : заявл. 28.07.1998; опубл. 17.06.2002. Бюл. №6.
10. Укрзалізниця отримала перші рейкозварювальні машини на платформі Volvo Trucks. Rail.insider. 04.06.2020 URL : https://www.railinsider.com.ua/ukrzaliznyczya-otrymala-pershi-rejkozvaryuvalni-mashyny-na-platformi-volvo-trucks/ .
11. Спосіб пресового зварювання дугою, керованою магнітним полем : пат. 46036 Україна, МПК В23К 9/08 (2006.01); заявл. 21.01.1998; опубл. 15.05.2002. Бюл. №5.
12. Kachinsky V.S., Kuchuk-Yatsenko S.I. Joint formation in magnetically-impelled arc butt welding of thick-walled pipes from high-strength steels. The Paton Welding Journal. 2017. № 8. P. 39-45.
13. Качинський В.С., Кучук-Яценко С.І., Коваль М.П. Пресове зварювання магнітокерованою дугою високоміцних сталевих трубчастих деталей гідро циліндрів. The Paton Welding Journal. 2020. № 1. P. 45-50.
14. Кучук-Яценко С.І., Качинський В.С., Коваль М.П. Розробка технології та обладнання для пресового зварювання трубчастих деталей в умовах виробництва з метою економії ресурсу та підвищення надійності високонавантажених виробів. The Paton Welding Journal. 2020. № 10. С. 3-7.
15. Chen Haidong, MA Tiejun, Zhang Yong, Zhang Xiaoyu. Microstructural analysis of mild steel joint by flash butt welding with external magnetic field. Transactions of the China welding institution. 2012. (2). 109-112.
16. Спеціальні способи зварювання : підручник / І.В. Крівцун, В.В. Квасницький, С.Ю. Максимов, Г.В. Єрмолаєв, за заг. ред. академіка НАН України, д.т.н., проф. Б.Є. Патона. Миколаїв : НУК, 2017. 346 с.
Copyright (c) 2024 Viktor Oshovskyі, Igor Kapura, Oleksandr Shostak
Prospects of Modern Methods of Butt Welding for the Manufacture of Blanks and Repair of Crankshafts
About the Authors
Viktor Oshovskyі, Associate Professor, PhD in Technics (Candidate of Technics Sciences), Pervomaisky Educational and Research Institute of Admiral Makarov National University of Shipbuilding, Pervomaysk, Ukraine, e-mail: oshovskyvikt@ukr.net, ORCID ID: 0000-0002-8065-907X
Igor Kapura, PhD in Technics (Candidate of Technics Sciences), Senior lecturer, Pervomaisky Educational and Research Institute of Admiral Makarov National University of Shipbuilding, Pervomaysk, Ukraine, ORCID ID: 0009-0008-1695-389X
Oleksandr Shostak, Senior lecturer, Pervomaisky Educational and Research Institute of Admiral Makarov National University of Shipbuilding, Pervomaysk, Ukraine, ORCID ID: 0000-0003-4461-1009
Abstract
The purpose of the study is to analyze modern productive automated methods of electrostatic welding that are promising for technologies for manufacturing blanks or repairing steel crankshafts from prefabricated parts to replace stamping, forging, and other unproductive methods, as well as to increase material utilization, quality, reliability, and the possibility of implementing these methods at engine-building enterprises. It is noted that the existing stamping methods cause shape deviations when the crankshafts are twisted. And when forging large shafts, due to the need to simplify the workpiece, adjacent jowls and connecting rods are combined with large overlaps, which contribute to a very low material utilization rate, a decrease in reliability due to fiber cutting when they are cut. In addition, there are shape errors in the heat treatment process of crankshafts - bending of the workpiece, which is a very time-consuming and costly operation, “turning the crank arm over” during the settling process, which is determined as the main defect in the shaft shape. The manufacture of large shafts requires specialized enterprises with unique pressing equipment and highly qualified workers. It is proposed to manufacture crankshafts from prefabricated journals with half journals, or journals and journals by modern methods of electrostatic welding, automated by computer control - small shafts with pulsating melting; and large shafts with melting by a controlled arc rotating in an Archimedean spiral under the action of a radial magnetic field of solenoids. To increase efficiency, it is proposed to further enhance the magnetic induction of the field with neodymium magnets. The proposed methods of manufacturing and repairing crankshafts will increase the material utilization rate to the maximum, reduce shaft shape errors by eliminating heat treatment after manufacturing or repair, obtain high quality and reliability of shafts, and automate the manufacturing process.Keywords
Full Text:
PDFReferences
1. Dobrianskyi, S.S., Malafeev Yu.M., & Puhovskyi, Ye.S. (2014). Design and production of blanks: a textbook. Kyiv: NTUU «KPI» [in Ukrainian].
2. Klemeshev, Ye.S. (2018). Development of theoretical and technological foundations of the metal-saving process of forging connecting rod journals of large crankshafts. Thesis for the degree of candidate of technical sciences. Dnipro: National Metallurgical Academy of Ukraine [in Ukrainian].
3. Milenin, A., Rec, T., Walczyk, W., & Pietrzyk M. (2014). Model of curvature of crankshaft blank during the heat treatment after forging. Procedia Engineering, 81, 498-503 [in Poland].
4. Miao, J., Shiyan, Z, Baofeng, G., & Qun L. (2010) Study on bending and upsetting forging 305 marine crankshafts. Advanced Materials Research, 101, 337 – 343 [in Switzerland]. DOI : 10.4028/www.scientific.net/AMR.97-101.337
5. Sologyb, M.A., Rozhnetskyi, O.I., Nekoz, O.I., Gorpenyuk M.A., & Preys G.O. (2002). Technology of structural materials: a textbook. M.А. Sologyb (Ed). Kyiv: Vycha Shkola [in Ukrainian].
6. Beloev, M., Khomenko, V.I., & Kuchuk-Yatsenko S.I. (2013) Selection of welding technologies in construction of large-diameter main pipelines. The Paton Welding Journal, 10/11, 131-134 [in Ukrainian].
7. Kuchuk-Yatsenko, S.I., Shvets, V.I., Didkovsky, A.V., Antipin, E.V., & Kapitanchuk, L.M. (2013) Defects of joints of high-strength rails produced using flash-butt welding. The Paton Welding Journal, 9, 2-8 [in Ukrainian].
8. Kuchuk-Yatsenko, S.I., Rudenko, P.M., Didkovsky, A.V., & Antipin, Ye.V. (2021) Operational control of the process of resistance butt welding of railway rails using the pulsed arc method. The Paton Welding Journal, 5, 8-14 [in Ukrainian].
9. The method of resistance butt welding: Patent 46820 Україна : МПК В23К 11/04 (2006.01). (22) : 28.07.1998; (46) : 17.06.2002. Bulletin 6.
10. Ukrainian Railways received the first rail welding machines on the Volvo Trucks platform. Rail.insider. 04.06.2020 URL : https://www.railinsider.com.ua/ukrzaliznyczya-otrymala-pershi-rejkozvaryuvalni-mashyny-na-platformi-volvo-trucks/ .
11. Method of press welding with a magnetic field controlled arc : patent 46036 Україна, МПК В23К 9/08 (2006.01); (22) : 21.01.1998; (46) : 15.05.2002. Bulletin 5.
12. Kachinsky, V.S., & Kuchuk-Yatsenko, S.I. (2017) Joint formation in magnetically-impelled arc butt welding of thick-walled pipes from high-strength steels. The Paton Welding Journal, 8, 39-45 [in Ukrainian].
13. Kachinsky, V.S., Kuchuk-Yatsenko, S.I., & Koval, М.P. (2020) Press welding of high-strength steel tubular parts of hydraulic cylinders with magnetically controlled arc. The Paton Welding Journal, 1, 45-50 [in Ukrainian].
14. Kuchuk-Yatsenko, S.I., Kachunskyi, V.S., & Koval, M.P. (2020). Development of technology and equipment for press welding of tubular parts in production conditions to save resources and improve the reliability of highly loaded products. Paton Welding Journal, 10, 3-7 [in Ukrainian].
15. Chen, Haidong, MA, Tiejun, ZHANG, Yong, & ZHANG, Xiaoyu. (2012) Microstructural analysis of mild steel joint by flash butt welding with external magnetic field[J]. Transactions of the China welding institution, 2, 109-112 [in China].
16. Krivtcun, I.V., Kvasnytckyi, V.V., Maksymov, C.Yu., & Yermolayev, G.V. (2017). Special welding methods: a textbook. B.Ye. Paton (Ed). Mykolayiv: NUK [in Ukrainian].
Citations
1. Добрянський С.С., Малафєєв Ю.М., Пуховський Є.С. Проектування і виробництво заготовок / підручник. К. : НТУУ «КПІ», 2014. 353 с.
2. Клемешов Є.С. Розвиток теоретичних та технологічних основ металозаощаджувального процесу кування шатунної шийки великогабаритних колінчастих валів : дис. вч. cтупеня канд. техн. наук : 05.03.05. Дніпро : Нац. металург. акад. Укр., 2018. 158 с.
3. Milenin A., Rec T., Walczyk W., Pietrzyk M. Model of curvature of crankshaft blank during the heat treatment after forging. Procedia Engineering, AGH Krakow. 2014. Vol. 81. P. 498-503.
4. Miao, J. Z., Shiyan, G., Baofeng, L. Qun.Study on bending and upsetting forging 305 marine crankshafts. Advanced Materials Research, Switzerland. 2010. № 101. P. 337-343. DOI : 10.4028/www.scientific.net/AMR.97-101.337
5. Технологія конструкційних матеріалів : підручник. Вид. 2-ге, переробл. і допов. / М.А. Сологуб, І.А. Рожнецький, О.І. Некоз та ін.; за ред. М.А. Сологуба. К. : Вища шк., 2002. 374 с.
6. Beloev M., Khomenko V.I., Kuchuk-Yatsenko S.I. Selection of welding technologies in construction of large-diameter main pipelines. The Paton Welding Journal. 2013. № 10/11. Р. 131-134.
7. Kuchuk-Yatsenko S.I., Shvets V.I., Didkovsky A.V., Antipin E.V. Kapitanchuk, L.M. Defects of joints of high-strength rails produced using flash-butt welding. The Paton Welding Journal. 2013. № 9. P. 2-8.
8. Кучук-Яценко С.І., Руденко П.М., Дідковський О.В., Антіпін Є.В. Операційний контроль процесу контактного стикового зварювання залізничних рейок методом пульсуючого оплавлення. The Paton Welding Journal. 2021. № 5. С. 8-14.
9. Спосіб контактного стикового зварювання оплавленням : пат. 46820 Україна : МПК В23К 11/04 (2006.01) : заявл. 28.07.1998; опубл. 17.06.2002. Бюл. №6.
10. Укрзалізниця отримала перші рейкозварювальні машини на платформі Volvo Trucks. Rail.insider. 04.06.2020 URL : https://www.railinsider.com.ua/ukrzaliznyczya-otrymala-pershi-rejkozvaryuvalni-mashyny-na-platformi-volvo-trucks/ .
11. Спосіб пресового зварювання дугою, керованою магнітним полем : пат. 46036 Україна, МПК В23К 9/08 (2006.01); заявл. 21.01.1998; опубл. 15.05.2002. Бюл. №5.
12. Kachinsky V.S., Kuchuk-Yatsenko S.I. Joint formation in magnetically-impelled arc butt welding of thick-walled pipes from high-strength steels. The Paton Welding Journal. 2017. № 8. P. 39-45.
13. Качинський В.С., Кучук-Яценко С.І., Коваль М.П. Пресове зварювання магнітокерованою дугою високоміцних сталевих трубчастих деталей гідро циліндрів. The Paton Welding Journal. 2020. № 1. P. 45-50.
14. Кучук-Яценко С.І., Качинський В.С., Коваль М.П. Розробка технології та обладнання для пресового зварювання трубчастих деталей в умовах виробництва з метою економії ресурсу та підвищення надійності високонавантажених виробів. The Paton Welding Journal. 2020. № 10. С. 3-7.
15. Chen Haidong, MA Tiejun, Zhang Yong, Zhang Xiaoyu. Microstructural analysis of mild steel joint by flash butt welding with external magnetic field. Transactions of the China welding institution. 2012. (2). 109-112.
16. Спеціальні способи зварювання : підручник / І.В. Крівцун, В.В. Квасницький, С.Ю. Максимов, Г.В. Єрмолаєв, за заг. ред. академіка НАН України, д.т.н., проф. Б.Є. Патона. Миколаїв : НУК, 2017. 346 с.