Abstract
The article is devoted to the substantiation of technological foundations for the restoration of extremely worn-out, metal-consuming, and resource-consuming parts, in a method consisting of applying a compensating metal wear with subsequent plastic deformation. Currently, there are no technologies for their restoration in a repair facility that guarantee the resilience of the factory product. The proposed technological process of repair consists of butt welding onto the end of the spline semi-axle shank, compensating for the wear of the metal, the volume of which takes into account the losses resulting from the wear of the slots, as well as allowances for their machining. In the example of forging the axle shaft of a truck’s driving axle, the regularities of the plastic flow of metal during part deformation in the stamp are revealed. In the process of hot volumetric upsetting of long cylindrical parts with a variable diameter, it is important to know the possible directions of metal movements, as well as the energy-power characteristics of the process at various stages of forging. The evaluation criteria of the level of perfection of the technology were indicators of resource conservation and efficiency of the recovery route. The technological direction of the conducted research was analyzed, step by step, from the standpoint of saving repair materials and energy resources. The results of theoretical studies are crucial in the design of die tooling, for the manufacture of blanks, when restoring the rear axle shafts of trucks with pressure. Production tests carried out on the models, obtained as a result of mathematical processing of experimental data, confirmed the reliability of the experimental information. The introduction of the proposed set of repair equipment for the restoration of semi-axles will allow the formation of additional production in the region for the recycling of worn-out metal-intensive steel parts of agricultural machinery.
Highlights
The proposed technological process of repair consists of butt welding onto the end of the spline semi-axle shank, compensating for the wear of the metal, the volume of which takes into account the losses resulting from the wear of the slots and allowances for their machining [3]
The purpose of this work is to substantiate the possibility of using resource-saving renovation technology for the restoration of extremely worn metal-intensive steel parts by hot plastic deformation combined with butt welding of compensating metal wear, using the example of rear semi-axles in trucks, which is consistent with the modern direction of reuse of secondary raw materials currently undergoing economically unjustified disposal
The restoration of worn-out long-spline semi-axles with a cylindrical shank includes butt welding a cylindrical compensator, the length of which is selected based on the volume of worn metal and allowances for subsequent cutting, to the non-working end face, after which the workpiece is locally heated in the area of the worn spline surface to the metal ductility temperature, and its one-sided sediment is placed in a die with a detachable matrix punch, with a force specified in the direction of reduction, which makes it possible to achieve some reduction in the load on the deforming tool, while increasing the durability of the die tooling
Summary
It is especially important to apply waste-free and fast-paying recovery technologies to metal parts that have been subjected to energy-intensive remelting, until now. The known methods of restoration and hardening of such parts do not provide the identity of their new physical and mechanical properties, or indicators of their reliability. The restoration process should be highly productive, as close as possible to the factory production process, economical, and manageable. These requirements are met by the technological process of restoring parts using hot plastic deformation, with preliminary application of metal, compensating for Sustainability 2022, 14, 16.
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