High Dynamic Loads Research Articles

Экспериментальное исследование деформированного состояния металлоконструкций грузовых тележек кранов мостового типа с универсальной компоновочной схемой

Deformations of the supporting metal structures of machines for various purposes have a significant impact on the performance of the equipment installed on them. Insufficient rigidity of a metal structure can cause jamming and failure of drive elements and working bodies of material handling, construction and road machines, the operation of which is associated with the impact of high static and dynamic loads. Therefore, when designing new structural schemes of load-bearing metal structures, special attention must be paid to the issue of ensuring the necessary rigidity. The presented work contains the results of an experimental assessment of the deformed state of physical models of the metal structures of load trolleys of overhead cranes, made on the basis of a multipurpose layout drawing using various types of connections of bearing elements. The article reflects information about the methodology of experimental research, describes the features of the physical models of metal structures used in the course of the experiment. The data on the vertical displacements of the control points of metal structures when using various loading schemes are given. An assessment was made of the influence of the type of applied connections of load-bearing elements on the features of the resulting deformed state of the metal structure. A comparative analysis of experimental data and calculated values of vertical displacements of points of metal structures obtained as a result of computer simulation of the formed state using various finite element models is performed.

An optical method to monitor transparent contact interfaces during high frequency shear vibration cycles

Contacting interfaces provide frictional damping in jointed structures subjected to high dynamic loads. Predicting this frictional damping during vibration cycles is highly important since it strongly affects the dynamic response of the assembly and hence the lifetime of parts. Since frictional damping is heavily influenced by the contact condition at the interface, the most direct and insightful approach is thereby to actively monitor the contact interface. Although several methods have already been proposed to monitor the contact interfaces quasi-statically or in pre-sliding, such as digital image correlation, X-Ray and ultrasound, only limited data is available of the frictional interface behaviour during high frequency vibration.To provide a better insight into the contact interface behaviour during high frequency cyclic motion, an optical method is here developed based on transparent friction specimens and total internal reflection, and applied to an existing friction test rig. The resulting measurements across the whole interface show a large variation in the real area of contact during each vibration cycle, which could be linked to the kinematics of the contact interface. This large variation is observed for the first time in high frequency oscillating contacts and is attributed to ageing effect and fracture of asperities. These two effects dominate the contact mechanism at different sliding velocities and induce variations in the real area of contact during each vibration cycle. These results suggest that the mechanisms behind high frequency contact behaviour are more complex than what commonly assumed in dynamics simulations.

Inverse Heat Transfer Analysis Method to Determine the Entropic Coefficient of Reversible Heat in Lithium-Ion Battery

An entropic coefficient of reversible entropic heat is a key parameter in determining the battery thermal responses, but its measurement is challenging due to time consuming and inaccurate traditional methods. In this regard, an analytical approach based on the inverse heat transfer problem is newly proposed to precisely determine the entropic coefficient with low experiment cost. Experiments are conducted by discharging the battery under four different current rates to inversely estimate the entropic coefficients, and the least squares regression are conducted to optimize the derived entropic coefficients. Through the comparison with the existing potentiometric method, the experimental time can be reduced by 93.7%. Furthermore, the accuracy of the proposed method is well verified by validating within the root mean square error of 0.848°C by comparing with the experimental results. Through the validation processes under various operating conditions, such as low to high current rates, charging process, dynamic loads, and different ambient temperatures, the proposed method is proven over temperatures ranging from 10°C to 60°C. Conclusively, the proposed method can be a great alternative to replace the classical experimental methods.

Safety Assessment of High Dynamic Pre-Loaded Lithium Ion Pouch Cells

The knowledge of the influence of high dynamic loads on the electrical and mechanical behavior of lithium-ion cells is of high importance to ensure a safe use of batteries over the lifetime in electric vehicles. For the first time, the behavior of six commercial Li-Ion pouch cells after a constrained short-time acceleration (300 g over 6 ms) with a resulting cell surface pressure of 9.37 MPa was investigated. At this load, two out of six cells suffered from an internal short circuit, showing several damaged separator layers across the thickness in the area of the cell tabs. For the cells that remained intact, a range of measurement techniques (e.g., inner resistance measurement, electrochemical impedance spectroscopy (EIS), or thermal imaging) was used to reveal changes in the electrical property resulting from the load. The cells without short circuit show an increase of internal resistance (average of 0.89%) after the dynamic pre-load. The electric circuit model based on the EIS measurement indicates a decrease of the resistance R1 up to 30.8%. Additionally, mechanical properties of the cells in an abuse test subsequent to the dynamic pre-load were significantly influenced. The pre-loaded cell could sustain an 18% higher intrusion depth before electrical failure occurred as compared to a fresh cell in an indentation test. The results of this study revealed that a high acceleration pulse under realistic boundary conditions can lead to critical changes in a battery cell’s properties and needs to be taken into account for future safety assessments.

Deformation and Failure Laws of Surrounding Rocks of Coal Roadways under High Dynamic Load and Intelligent Prediction

Under high dynamic load, roadway deformation and failure may occur, posing great challenges. As for now, few studies have been carried out on the impacts of various factors on the deformation of roadway surrounding rocks under high dynamic load, not to mention those on intelligent prediction of the deformation and failure laws. This paper fills these research gaps by studying the deformation and failure characteristics of roadway surrounding rocks and the intelligent prediction method under high dynamic load. The finite difference software Flac3D was used to analyze the influences of roadway buried depth, lithology, and side pressure coefficient on the stability of surrounding rocks and a model was constructed for deformation prediction under high dynamic load. Finally, the influence of various factors on the deformation and their weight was obtained and the deformation can be predicted in line with the BP neural network prediction theory. The results show that the prediction effect is good, with high accuracy.

Numerical Investigation into the Mechanical Behaviours and Energy Characteristics of Hard Coal Subjected to Coupled Static-Dynamic Loads

In practical engineering, coal burst is usually caused by the combination of high geo-stress and dynamic loading. To study the dynamic response of coal in geo-stress conditions, numerical models of a coupled static–dynamic split Hopkinson pressure bar (SHPB) test system were established, based on which impact tests for coal specimens at different impact speeds and static pre-stress levels were conducted. The mechanical properties, energy characteristics and failure patterns of coal specimens under coupled static and dynamic loads were analyzed. The results show that when the pre-stress is constant, peak stress, the maximum strain energy and the maximum kinetic energy increase significantly with impact speed. Nevertheless, they are less affected by the static pre-stress, increasing linearly with a pre-stress level under lower impact speeds but becoming stable under higher impact speeds. In addition, weak dynamic loads may trigger the instability of the coal specimen in a high pre-stress condition. Overall, both the impact speed and static pre-stress have influence on the mechanical behavior and energy characteristics of coal specimens under coupled static and dynamic loads, but the influence of the impact speed outweighs that of the static pre-stress.

изико-механические свойства керамических покрытий, получаемых короткоимпульсной лазерной наплавкой порошковой смеси на основе бора

Modern repair production that implements traditional technologies for making restorative coatings has lost its relevance, since it cannot provide the necessary physical and mechanical properties of the coatings. The problem is that in modern metallurgy there is no line of repair additive materials with high strength and technological properties. Therefore, the issues of searching for innovative materials and technologies for their application on the surface of worn parts are relevant and require fundamental research. The aim of the work is to study the physical and mechanical properties of ceramic coatings obtained by short-pulse laser treatment. To achieve this goal, ceramic compositions based on boron carbide, additionally doped with boron nitride (0 to 40% BN), magnesium oxide (2 to 10% MgO) and lithium (5 to 25% LiO), were used. The scientifi c novelty of the research lies in the application of selective laser sintering technologies in the formation of thin coatings (up to 200 μm) under conditions of a short-pulse laser refl ow of powder media. To assess the physical and mechanical properties, laboratory research methods were used, in particular, analysis of the microhardness of the created restorative coatings, microstructure and tribological performance indicators using modern techniques and instrumentation. The research results confi rm the possibility of practical implementation of restorative coatings based on ceramic compounds. The multi-layer ceramic coatings (B4C-BN- MgO-Li2O) up to 200 μm thick showed good workability, low coeffi cient of friction (0.18) and the ability to work under high dynamic loads in the absence of intensive lubrication. The structure of the coatings has a dense adhesive zone with no visible defects. The presented results of studying the physic-mechanical properties of ceramic coatings have high research credentials and practical signifi cance, and their application will improve the durability of machine parts in the conditions of their operation.

Computational approach to thermal-stressed state modeling of tire based on the algorithm of its self-heating analysis . Part 1 – Theoretical basics of the approach

Elastomers and their composites are widely used in modern innovative technology: for the production of aviation and automobile tires, anti-vibration elements (rubber, rubber-metal springs), dampers, elastomeric bearings. Also they are used in shaft suspensions, as spacers between structural parts, supporting parts and fasteners. Elastomeric elements of structures have a high dynamic load, in particular of a cyclic nature, which is accompanied by the formation of hysteresis loops and, as a result, the occurrence of the phenomenon of self-heating. An increase in temperature in the middle of materials causes significant changes in their mechanical properties, reduces strength characteristics, accelerates aging and degradation processes, and has a significant impact on fatigue processes. In addition, an increase in temperature causes an additional thermal stress state, capable of significantly changing the qualitative picture of the structure's deformation characteristics' distribution. Thus, the purpose of this study is development of approach to assessing the thermal stress state of structures made of elastomeric materials for the possibility of further analysis of its influence on the structure work as a whole. The appropriate approach was built on the basis of numerical modeling of thermal and deformation processes which takes place into the structure during operation. The proposed approach includes several related calculations by using FEM and is based on the fundamental approaches of the theories of elasticity and viscoelasticity, thermal conductivity and thermo-elasticity. Thus, the article presents an approach to the analysis of the thermal stress state of structural elements under operating conditions. This approach was applied to determine the thermo-strain-stress characteristics of a pneumatic tire and corresponding pictures of its distribution were obtained.

Different ways for HAZ microstructure preparation and testing on high alloy steel

The heat-affected zone (HAZ) is the part of the weld that is affected by the heat generated by the welding process during welding. The microstructure of the HAZ is very heterogeneous and consists of different zones such as the coarse-grained HAZ, the fine-grained HAZ, the intercritical HAZ, and the over-tempred HAZ [1]. All these zones are very narrow and their properties are slightly different. These properties affect the integrity of the entire weld, so in many cases the HAZ may be the worst part of the weld. Another challenge is determining the properties of the individual HAZ regions, since the entire HAZ is very narrow and inhomogeneous. For this reason, many properties cannot be determined accurately, with the exception of a few, such as hardness, for which only a small region is sufficient for measurement. Therefore, it is important to know how to produce the individual microstructure of a HAZ in a wider range of the material in order to determine the actual properties of such a HAZ. One of the ways is to measure the welding parameters during welding to determine the actual influence of the thermal cycle on the formation of the invidual microstructure of HAZ in the weld. Moreover, it is crucial to repeat this weld thermal cycle in an unaffected base metal on a thermal welding simulator to obtain a suitable microstructure of the HAZ [1,2]. The second option is to prepare the microstructure in the furnace by slow heating which is followed by rapid cooling [1,3]. Both processes must be precise and accurate to obtain suitable HAZ microstructures. This article addresses the challenges of producing HAZ microstructures on the high-alloy steel CT781, which is widely used in the automotive industry for parts subjected to high dynamic loads.

Effect of polyurea coating with different mechanical properties on blast resistance of aluminum alloy circular tube structures: Experiments vs numerical simulations

Polyurea has attracted extensive attention in the field of anti-blast protection over the past few years. Two types of polyurea were prepared and their quasi-static and dynamic mechanical properties were examined to investigate the effect of polyurea coating with different mechanical properties on the blast resistance of the metal circular tube structure. A set of automatic spray equipment was designed and manufactured to spray polyurea efficiently on the circular tube structure. On that basis, the anti-blast test was performed using the two types of polyurea coated on the surface of 6063-T5 aluminum alloy circular tubes with different thicknesses. The macro and micro damage characteristics of polyurea coated aluminum tubes were obtained using the field tests, the metallographic microscope and the scanning electron microscope (SEM) technology. Numerical simulation models were built to elucidate the dynamic response process. The results suggest that polyurea is capable of significantly enhancing the blast resistance performance of the aluminum alloy circular tube. In contrast, polyurea with better energy absorption effect under high dynamic load may not exhibit higher protective efficiency. Whether the polyurea and the aluminum tube can always maintain the adhesion relationship and deformation together under the action of blast has been confirmed as a vital factor. Lastly, the energy absorption mechanism and influence mechanism of different kinds of polyurea were revealed using the Fourier Transform Infra-Red (FTIR) technology in accordance with the stress wave theory.

Nature-Inspired Design and Advanced Multi-Computational Investigations on the Mission Profile of a Highly Manoeuvrable Unmanned Amphibious Vehicle for Ravage Removals in Various Oceanic Environments

Recent large-scale operations, including frequent maritime transportation and unauthorised as well as unlawful collisions of drainage wastes, have polluted the ocean’s ecology. Due to the ocean’s unsuitable ecology, the entire globe may experience drastic aberrant conditions, which will force illness onto all living things. Therefore, an advanced system is very necessary to remove the undesired waste from the ocean’s surface and interior. Through the use of progressive unmanned amphibious vehicles (UAV), this study provides a dynamic operational mode-based solution to damage removal. In order to successfully handle the heavy payloads of ravage collections when the UAV reveals centre of gravity concerns, a highly manoeuvrable-based design inspired by nature has been imposed. The ideal creatures to serve as the inspiration for this piece are tropical birds, which have a long tail for navigating tricky situations. The design initialization was carried out by focusing on the outer body of tropical birds. Following this, special calculations were conducted and the full design parameters of the UAV were established. This study proposes a unique mathematical formulation for the development of primary and secondary design parameters of an UAV. The proposed mission profile of this application is computationally tested with the aid of sophisticated computational methodologies after the modelling of this UAV. The computational methods that are required are one-way coupling-based hydro-structural interaction assessments and computational hydrodynamic analyses. Computing is used to determine the aerodynamic and hydrodynamic forces over the UAV, the lightweight materials to withstand high fluid dynamic loads, and the buoyancy forces to complete the UAV components. These computational methods have been used to produce a flexible and fine-tuned UAV design for targeted real-time applications.

Experimental study of dynamic bond behaviour between corroded steel reinforcement and concrete

Corrosion damage of steel reinforcement is detrimental to the load-carrying capacity of reinforced concrete structures because it not only reduces the cross sectional area and strength of reinforcement bars, but also weakens the bond between reinforcement and concrete. Many studies have investigated the effects of corrosion on reinforcement loss and static bond strength between reinforcement and concrete, but no study of the influence of corrosion damage on dynamic bond strength has been reported yet. In this study, laboratory tests were conducted to investigate the effect of corrosion on the bond behaviour between steel reinforcement and concrete subjected to high rate dynamic load. Accelerated corrosion damage was induced to steel bars embedded in concrete specimens under laboratory condition. The bond parameters of steel reinforcement and concrete including the ultimate bonding load and bond-slip relationship corresponding to the various strain rates and corrosion degrees were obtained through dynamic pull-out tests. The empirical formulae of dynamic increase factors (DIFs) of the ultimate bonding strength corresponding to different corrosion levels and strain rates were proposed. The experimental results show that the strain rate effect on bonding behaviour is prominent irrespective of the corrosion level. The increase in the ultimate bonding strength with strain rate for the heavily corroded reinforcement (η = 5 %-10 %) is more prominent than that for the slightly corroded reinforcement (η = 0 %-5%). The decrease in the ultimate pull-out force caused by the corrosion damage at high strain rate is more pronounced than that at low strain rate. Corrosion-induced crack and the tensile strength of concrete have significant effect on both the static and dynamic bond behaviours. The results presented in the paper can be used for better modelling and prediction of the responses of corroded reinforced concrete structures subjected to dynamic loads.

Study on Complex Theory Solution and Numerical Simulation of Fracture Mechanics of Surrounding Rock Stress and Energy Field in Fault Type Rock Burst Stope

Rock burst is one of the most sophisticated and threatening problems in the process of mining activities of underground coal mines, which can evolve into phenomena such as gas outburst, violent ground pressure behavior of surrounding rock of stope roadway, and high dynamic load energy event of roof overburden fracture through the interaction between various influencing factors. This paper deeply studies the causes, consequences, and disaster mechanism of “2–2 rock burst accident” in Xinjulong coal mine, gives the network diagram of the relationship between the main influencing factors of fault type rock burst and high-energy events, establishes a mechanical model on this basis, and explores the influence and evolution law of fault influencing factors on the elastic strain energy field of surrounding rock of stope roadway.

Water hammer issues in refurbishment of a high-head hydropower plant equipped with Francis turbine

Refurbishment and upgrading of ageing hydropower plants contribute to increase of renewable energy share in modern electrical grid systems. The potential increase of discharge and flexibility of load variation may result in much higher dynamic loads on both refurbished and non-refurbished plant components during transient operating events. First, water hammer control strategies are outlined including operational scenarios, surge control devices, redesign of the pipeline components, or limitation of operating conditions. Water hammer models and solutions are briefly discussed in the light of their capability, availability and uncertainty. The core of the paper is devoted to investigations of water hammer effects in a high-head hydropower plant Piva, Montenegro which is currently in the final phase of refurbishment. The flow-passage system of the Piva HPP is comprised of the intake structure, followed by three parallel penstocks each with Francis type water turbine at the downstream end. The outlet part starts with three parallel draft tubes that are connected to a common lower orifice-type surge tank followed by tailrace tunnel and outlet structure. Computed and measured results for a selected emergency shut-down (ESD) of one turbine form full-load are compared and discussed. Then the validated computational model is used for simulation of ESDs for a wide operating range.

Flow-through and forming mechanism of laser shock micro-coining

Sheet-bulk metal forming (SBMF) is an advanced technology to efficiently produce high-quality parts based on high resource utilization. Coining, a kind of SBMF, can be used to fabricate functional and decorative microstructures. In this paper, a new method called laser shock micro-coining (LSMC) is proposed based on the unique advantages of intense pulsed laser of high strain rate dynamic loading characteristics and suitable for micro-forming. However, smaller sheet thickness will lead to the emergence of flow-through. In this paper, ALE model and SPH-FEM model are established for numerical simulation to study LSMC. Through numerical simulation and experiment, the forming mechanism and improvement methods of flow-through are studied, and the appropriate research parameters are determined. The material flow, forming mechanism, stress wave propagation mechanism and forming uniformity are studied. Results show that the lack of material near the projections and the unique inverse plastic deformation in dynamic forming are the important factors leading to flow-through. Suitable laser energy and large sheet thickness as well as the existence of the punch can inhibit the formation of flow-through from one or two aspects. Under dynamic forming, the material has high forming rate and good filling properties. Material deformation is related to the propagation of stress wave. The propagation of stress wave and the height of sheet metal result in a unique short rod mechanism. The process has good forming uniformity, and a more uniform forming effect can be obtained by appropriately increasing the laser energy.

Detection of impulsive signals on tendons for hybrid wind turbines using acoustic emission measurements

The power generation of a wind turbine is determined, among other things, by its hub height. In recent years, a new, effi-cient and economical design for high wind turbine towers called hybrid towers is developed consisting of two sections. The lower section consists of prefabricated concrete ring segments that are post-tensioned together and assembled at the tur-bines site, whereas the connected upper section is composed of conventional steel rings. The prestressed tendons in the lower section are located inside the tower and ensure the stability of the wind turbine. Thus, these are critical elements and any damage to them should be detected as early as possible. The tendons are often highly prestressed and exposed to high dynamic loads. Fatigue failure in the prestressing steel is a potential risk. As the tendons are covered in plastic pipes and in some sections have contact to the concrete segments the access is limited for inspections. The aim of the presented inves-tigations is the development of a monitoring approach for the immediate detection of the occurring wire breaks. Acoustic emission measurement has been proved to be a promising technique for that and thus should be assessed. For experiments tendons were prestressed in a test frame with the dimensions of 12 x 4.1 m analogous to the boundary conditions of a real wind turbine. Wire breaks as well as wire break-like signals were generated on tendons, which are recorded by piezoelectric sensors and analyzed by a measuring device. The results show that by acoustic emission measurement the wire break signals can be well recorded. The results from the large-scale experiments are transferred towards the application at real structures.

Evaluation of capacity of power hammer machine foundation from high strain dynamic load test: Field test and axisymmetric numerical modeling

The power hammer machines induce harmful vibrations in different parts of the foundation which may result in excessive dynamic settlement. While designing the hammer machine foundation, variety of static and repetitive impact load tests are generally conducted to ensure both the stability and serviceability of the foundation system. The static load test (SLT) is performed in the case of such foundations to obtain the ultimate capacity. However, the SLT is unable to predict the reliable response of the machine foundation. Hence, the current study is aimed to investigate the static and dynamic resistance of power hammer machine foundation by employing the high strain dynamic load test (DLT). The test procedure involves measuring the acceleration, axial force and settlement at the top of the machine foundation. Additionally, the soil resistance pertaining to damping is assumed to disappear with the zero-velocity at the first moment, which is identical to the unloading point method (UPM). Also, the field test and axisymmetric finite element analysis by considering the nonlinear soil model were performed to evaluate the stress settlement curve (SSC) from both SLT and DLT. The results reveal that the capacity of the machine foundation subjected to repetitive dynamic loads increases gradually and then tend to remain stable in case of additional impact loads. The SLTs showed 3–4 % higher static resistance than the first DLT and 8–9 % reduction in contrast to the second DLT. Moreover, the residual plastic deformation of the soil beneath the machine foundation was recorded to rapidly increase at the beginning of hammer tamping while it decreased steadily with further increasing of the hammer blows.

Simulation of loads on operating device of peat-cutting unit with regard to errors in the cutting elements arrangement

The practice of using units with milling-type operating devices showed their insufficient reliability, which leads to deterioration of the units’ performance. The reasons for this are high dynamic loads in structural members, which are caused by external resistance forces on a milling cutter. They have random, sharply variable nature due to structural heterogeneity of a peat deposit, its random physical and mechanical properties, the presence of wood inclusions in it, as well as periodic interaction of blades with the deposit, and many other factors. In this case, the parameters of actual milling cutter, due to manufacturing and installation errors, differ from those specified in the “ideal” design. In addition, wear and irreversible deformations of cutting elements (blades) occur during operation. As a result the position of blades in a cutter body differs from the “ideal” positioning pattern. The purpose of the paper is to develop a model of section moment on a milling cutter when interacting with a peat deposit in the process of technological operations, taking into account the influence of the error of blade positioning on a cutter body. Expressions for calculating the moment spectral density were obtained. Its characteristic features were analyzed. Errors in positioning of cutting elements on a cutter body lead to changes in the magnitude and nature of the load and its frequency content. In this case, new, additional components appear at frequencies multiple of the cutter’s angular velocity, enriching the load spectrum and increasing its variance. Their magnitude is determined by the cumulative value of the errors. As an example, an analysis of the influence of the error in positioning cutting elements on the spectral density for the operating device of MTP-42 deep milling machine is given. The study results are of practical value and should be taken into account in the calculation of dynamic loads in designing structural members of milling units, especially if their operating devices have a large number of blades, use fine feeds, and when the natural frequencies of the structural members are equal to or multiple of the angular speed of a milling cutter.

Influence of pitting corrosion on the fatigue strength of offshore steel structures based on 3D surface scans

Support structures for offshore wind turbines and the corresponding transformer platforms are highly susceptible to corrosion. In particular, the phenomenon of pitting is crucial, as it leads to local stress concentrations and thus affects the fatigue life of structures. Despite corrosion protection systems, corrosion cannot be completely avoided, which can lead to pitting corrosion on the steel surface. This leads to fatigue life reduction, since the structures are exposed to high dynamic loads. Local stress concentrations can be considered in local concepts but so far, corrosion effects in local concepts are insufficiently defined. Hence, this paper aims to investigate the impact of pitting corrosion and the corresponding stress concentration on the fatigue life endurance of structural steel, used for offshore wind support structures. For this purpose, a total of 36 pre-corroded specimens with pitting were tested against fatigue failure and monitored with Digital Image Correlation. In addition, the specimens were scanned with a high-resolution 3D scanner and converted to numerical models by reverse engineering, to determine the stress concentrations on the surface. In most cases the hotspots from the numerical model coincide with the crack location detected with Digital Image Correlation. The notch effect has a significant impact on the crack location and crack path.

Performability of electro-hydro-mechanical rotary head of drill rig in open pit mining: A case-study

The test subject is the electro-hydro-mechanical rotary-and-feed mechanism of roller-bit drill rigs with undermount rotary head. The goal of the research is the capacity stimulation, vibration reduction and reliability improvement of drill rig model SBSH-250MNA-32. The article describes the studies in the field of mining machines and the relevant engineering solutions. It is critical for Russia to preserve and replenish its mineral resources and mineral reserves to pursue social and economic advance. The priority growth of coal and gold production using the advanced open pit mining method can increase percentage of the latter in cumulative mineral mining by not less than 50%. Furthermore, it is necessary to cut down costs of production by 4–5%. The main and extremely labor consuming process in open pits in Russia is drilling which takes up to 40% of total mining cost [1–3]. The common method of drilling in rocks with the hardness factor of 6–20 on Protodyakonov’s scale in Russia is the roller-bit drilling [4–6]. This drilling processes is accompanied with high dynamic loading imposed on the rotary-and-feed mechanism [7–9]. One of the ways of reducing dynamic loads in the roller-bit drill rigs is redesigning of the rotary-and-feed mechanism to possess higher safety and anti-vibration properties, simpler structure, as well as better performability and longevity [7, 8, 10–13]. This article describes and substantiates the design and operating principle of the electro-hydro-mechanical rotary head, its prototype testing, the research program and procedure, the instrumentation preparation, the research objective as well as the test data processing and analysis as a case-study of drill rig model SBSH-250MNA-32.