Repairing of cracks on tooth gear ring of a bucket-wheel excavator
2023
Authors
Miladinov, MilanSedmak, Simon
Đorđević, Branislav
Sedmak, Aleksandar
Vučetić, Filip
Milivojević, Aleksandar
Conference object (Published version)
Metadata
Show full item recordAbstract
Bucket-wheel excavators are continuously working machines for removal of waste and useful materials in open-pit mines, mainly used for mining of lignite. The purpose of a tooth gear ring is to rotate the excavator using two reducers. Due to this, the structural integrity of such elements is of great importance for the safe and reliable operation of the bucket-wheel excavator as a whole. In order to ensure its proper function, non-destructive testing (NDT) methods (namely magnetic particles testing) was performed after casting of gears. NDT revealed the presence of cracks with varying lengths (10-110 mm), which were located in the gear teeth, its main body and the openings used for connections between segments. For this reason, it was necessary to adopt a repair welding technology which would eliminate the cracks. Since the tooth gear ring was made of GS-40MnCrSi3V low-alloyed cast steel, electrode 42 4 B 42 H5 (designation according to EN 499E) was selected as filler material, due to i...ts exceptional mechanical properties, suitability for welding of low-carbon low-alloyed steels and low hydrogen content. Manual arc welding was the procedure used in this case. Since these repairs were all performed on the surface of the tooth gear ring segments, final NDT included only magnetic particle and penetrant testing, both of which had shown that the repair technology was successfully applied, i.e. not new defects were detected in the repaired gear ring elements.
Keywords:
tooth gear ring / repair welding / bucket-wheel excavator / GS-40MnCrSi3V steelSource:
Second International Symposium on Risk Analysis and Safety of Complex Structures and Components (IRAS 2023), 2023, 48, 27-32Publisher:
- Elsevier B.V.
URI
https://www.sciencedirect.com/journal/procedia-structural-integrity/vol/48/suppl/Chttps://machinery.mas.bg.ac.rs/handle/123456789/7101
Collections
Institution/Community
Inovacioni centarTY - CONF AU - Miladinov, Milan AU - Sedmak, Simon AU - Đorđević, Branislav AU - Sedmak, Aleksandar AU - Vučetić, Filip AU - Milivojević, Aleksandar PY - 2023 UR - https://www.sciencedirect.com/journal/procedia-structural-integrity/vol/48/suppl/C UR - https://machinery.mas.bg.ac.rs/handle/123456789/7101 AB - Bucket-wheel excavators are continuously working machines for removal of waste and useful materials in open-pit mines, mainly used for mining of lignite. The purpose of a tooth gear ring is to rotate the excavator using two reducers. Due to this, the structural integrity of such elements is of great importance for the safe and reliable operation of the bucket-wheel excavator as a whole. In order to ensure its proper function, non-destructive testing (NDT) methods (namely magnetic particles testing) was performed after casting of gears. NDT revealed the presence of cracks with varying lengths (10-110 mm), which were located in the gear teeth, its main body and the openings used for connections between segments. For this reason, it was necessary to adopt a repair welding technology which would eliminate the cracks. Since the tooth gear ring was made of GS-40MnCrSi3V low-alloyed cast steel, electrode 42 4 B 42 H5 (designation according to EN 499E) was selected as filler material, due to its exceptional mechanical properties, suitability for welding of low-carbon low-alloyed steels and low hydrogen content. Manual arc welding was the procedure used in this case. Since these repairs were all performed on the surface of the tooth gear ring segments, final NDT included only magnetic particle and penetrant testing, both of which had shown that the repair technology was successfully applied, i.e. not new defects were detected in the repaired gear ring elements. PB - Elsevier B.V. C3 - Second International Symposium on Risk Analysis and Safety of Complex Structures and Components (IRAS 2023) T1 - Repairing of cracks on tooth gear ring of a bucket-wheel excavator EP - 32 SP - 27 VL - 48 DO - 10.1016/j.prostr.2023.07.106 ER -
@conference{ author = "Miladinov, Milan and Sedmak, Simon and Đorđević, Branislav and Sedmak, Aleksandar and Vučetić, Filip and Milivojević, Aleksandar", year = "2023", abstract = "Bucket-wheel excavators are continuously working machines for removal of waste and useful materials in open-pit mines, mainly used for mining of lignite. The purpose of a tooth gear ring is to rotate the excavator using two reducers. Due to this, the structural integrity of such elements is of great importance for the safe and reliable operation of the bucket-wheel excavator as a whole. In order to ensure its proper function, non-destructive testing (NDT) methods (namely magnetic particles testing) was performed after casting of gears. NDT revealed the presence of cracks with varying lengths (10-110 mm), which were located in the gear teeth, its main body and the openings used for connections between segments. For this reason, it was necessary to adopt a repair welding technology which would eliminate the cracks. Since the tooth gear ring was made of GS-40MnCrSi3V low-alloyed cast steel, electrode 42 4 B 42 H5 (designation according to EN 499E) was selected as filler material, due to its exceptional mechanical properties, suitability for welding of low-carbon low-alloyed steels and low hydrogen content. Manual arc welding was the procedure used in this case. Since these repairs were all performed on the surface of the tooth gear ring segments, final NDT included only magnetic particle and penetrant testing, both of which had shown that the repair technology was successfully applied, i.e. not new defects were detected in the repaired gear ring elements.", publisher = "Elsevier B.V.", journal = "Second International Symposium on Risk Analysis and Safety of Complex Structures and Components (IRAS 2023)", title = "Repairing of cracks on tooth gear ring of a bucket-wheel excavator", pages = "32-27", volume = "48", doi = "10.1016/j.prostr.2023.07.106" }
Miladinov, M., Sedmak, S., Đorđević, B., Sedmak, A., Vučetić, F.,& Milivojević, A.. (2023). Repairing of cracks on tooth gear ring of a bucket-wheel excavator. in Second International Symposium on Risk Analysis and Safety of Complex Structures and Components (IRAS 2023) Elsevier B.V.., 48, 27-32. https://doi.org/10.1016/j.prostr.2023.07.106
Miladinov M, Sedmak S, Đorđević B, Sedmak A, Vučetić F, Milivojević A. Repairing of cracks on tooth gear ring of a bucket-wheel excavator. in Second International Symposium on Risk Analysis and Safety of Complex Structures and Components (IRAS 2023). 2023;48:27-32. doi:10.1016/j.prostr.2023.07.106 .
Miladinov, Milan, Sedmak, Simon, Đorđević, Branislav, Sedmak, Aleksandar, Vučetić, Filip, Milivojević, Aleksandar, "Repairing of cracks on tooth gear ring of a bucket-wheel excavator" in Second International Symposium on Risk Analysis and Safety of Complex Structures and Components (IRAS 2023), 48 (2023):27-32, https://doi.org/10.1016/j.prostr.2023.07.106 . .