Additive technologies play an important role in modern automotive design and manufacturing, with their applications expanding every year. Originally used primarily for prototyping and mock-up production, 3D printing is now increasingly being used to manufacture key automotive components, with some companies offering fully 3D printed vehicles. This article analyzes the possibilities of printing load-bearing structures and the design of a key element - the electric motor mounting bracket for the TOQ car prototype. TOQ Prototype EV is an energy-efficient electric vehicle prototype being developed by the SU Racing Team from Satbayev University. The goal of the project is to create an ultra-light, durable, energy-efficient prototype vehicle with a long range of 1 kWh of energy. The use of new materials and additive technologies opens up the possibility of creating a variety of combinations, both for the production of parts with increased strength and for the use of advanced materials in the interior of the cabin. The process of prototyping an energy-efficient electric vehicle using additive manufacturing illustrates an innovative approach to improving energy efficiency and reducing energy consumption. This article details the process of designing an electric motor bracket using generative design and additive manufacturing. The study aims to evaluate the feasibility of 3D printing the load-bearing and critical elements of an electric vehicle prototype, as well as to simulate the loads when operating an electric motor with a peak power of 2 kW. f 2 kW. Mechanical engineering, automotive industry, additive manufacturing, 3D printing , industry 4.0, racing car, energy efficiency

https://doi.org/10.48081/CLSC9327

2024

Issue 3

An experimental rig for evaluating the operation of a centrifugal cantilever pump has been developed. The rig is equipped with an accelerometer, microphone, speed sensor, pressure gauge, vacuum gauge and water flow meter to measure vibration and cavitation. The rig is equipped with a frequency-controlled drive to adjust the shaft speed of the centrifugal cantilever pump. A ZET 017-U2 spectrum analyzer with 2 input channels and ZETLAB software is used to collect experimental data. The experimental rig for evaluating the operation of a centrifugal cantilever pump allows you to determine the following faults: misalignment, imbalance, faulty bearing, faulty impeller and mechanical weakness and cavitation phenomena. The operability of the experimental rig for evaluating the operation of a centrifugal cantilever pump has been checked. The operation of the equipped sensors of the rig has been tested: accelerometer, microphone, speed sensor. The developed stand was used to conduct experimental studies of the centrifugal cantilever pump CHP 32-160 by Karlskrona. The results of experimental studies of the centrifugal pump CHP 32-160, performed on this stand, are presented. Experimental studies of oscillations of the angular velocity of the centrifugal cantilever pump shaft were conducted. The root-mean-square values of the radial vibration velocity of the centrifugal cantilever pump bearings were determined, their analysis was carried out and recommendations were issued. The sound pressure spectrum of the centrifugal cantilever pump was determined. The spectrum analysis revealed cavitation phenomena in the centrifugal cantilever pump, recommendations for their elimination were given.

https://doi.org/10.48081/EAQI5770

2024

Issue 3

The article is devoted to the derivation of the dependence of energy consumption of soil planning works by a bulldozer equipped with a blade with a multi-level change in geometry on the change in the blade shape during the work and, accordingly, its current cutting and grip angles. A classification of works performed by bulldozer equipment is given. The article presents design schemes of promising blades with a multi-level change in geometry, a change in the geometric shape of the blade with the redistribution of the flows of the soil drag prism is analyzed in detail, the blade plane is shown at different angles with all points of application of forces and changes in specific angles affecting the shape and geometry of the blade. A brief overview of the derivation of the main mathematical dependencies is shown, according to which, depending on the position of the middle or side parts of the blade, a synchronous change in the grip and cutting angles occurs, which affect the redistribution of forces that impede cutting and soil planning. The article presents dependencies that allow calculating geometric parameters that determine the process of interaction with the soil of an adaptable blade with a multi-level change in geometry as a function of: the ratio of the length of the middle section to the maximum width of the blade grip, the installation angles of the hinges in the longitudinal and transverse planes of the bulldozer; the angle of rotation of the side sections relative to the hinges.

https://doi.org/10.48081/DWQM4458

2024

Issue 3

One of the current challenges in additive technology is the reinforcement with standard ribbed steel bars. A special automated reinforcement mechanism was developed to automatically produce reinforcement mesh from standard ribbed steel bars. The automated reinforcement mechanism arranges the reinforcement bars in both horizontal and vertical directions and uses spot contact welding to join them. During spot contact welding, heat is transferred through copper electrodes to the vertically and horizontally placed reinforcement bars being welded. Since the welding process occurs very quickly, it is impossible to visually monitor the heating and cooling of the vertically and horizontally arranged bars. To determine the temperature reached by the vertically and horizontally arranged bars during heating, as well as to precisely measure their heating and cooling times, a high-resolution InfraTec VarioCAM HD head thermal imager was used. This thermal imager showed that the welded bars heat up to over 150°C in 0.5 seconds and cool down to 37.9°C only after 49 seconds. This indicated the need for an additional cooling system for the automated reinforcement mechanism.

https://doi.org/10.48081/GMSL2529

2024

Issue 3

According to information from open sources, to date, ferrous metallurgy waste in excess of 6 billion tons is concentrated in the Republic of Kazakhstan. At the same time, the recycling of ferrous metallurgy waste does not exceed 2%. Such a low percentage of recycling and recycling of ferrous metallurgy waste is primarily due to the lack of interest from private business and the high cost of extracting metals and related components from man-made waste. One possible way to dispose of ferrous metallurgy waste is the possibility of using it as additives in the composition of heavy concretes. In the presented study, metallurgical slag of Casting LLP of various granulometric composition (from 0.5 to 10mm) was used as additives to the composition of heavy concrete. Control samples from the developed compositions of heavy concrete were tested for compressive strength. Prototypes of construction products of various nomenclature, subjected to compression testing, were produced from the highest quality compositions of concrete mixtures. As experimental data show, the composition of heavy concrete with the granulometric dimensions of metallurgical slag passing through a cell of 0.5 laboratory sieve, from which paving slabs were made, has the highest strength. At the same time, the compressive strength of the construction product was 99.69MPA. The lowest strength was shown by heavy concrete with a granulometric size of metallurgical slag of 2.5 mm. The compressive strength of the hollow wall stone was 1.746 MPA. At the same time, metallurgical slag with a granulometric size from 0.63 to 1.25 showed a compressive strength of at least 10MPA for hollow wall stone. Construction products made from such a composition can be used in places with heavy traffic, as well as in industries with aggressive environments. As a result of the tests, it was revealed that the granulometric size does not always affect the strength characteristics of a building product-this is primarily due to the percentage of metallurgical slag, cement grade, and the quality of the aqueous cement mortar.

https://doi.org/10.48081/NWNR2833

2024

Issue 3

This article presents the results of coercive force dependence study of on the chemical composition and geometric parameters for the purpose of identifying the steel grade in a non-destructive manner. The paper proposes to identify the steel grade by the coercive force, using a correlation with the carbon equivalent and the diameter of the rolled product. As a result of the work, the possibility of identifying steel grades by the carbon equivalent associated with the coercive force and the diameter of the product was established. The ranges of the carbon equivalent for steels St3, 18Mn2Si and 30CrMn2Si were determined. The results of the work established that the coercive force depends on the chemical composition and geometric parameters of the controlled product. Thus, the solutions proposed in this paper are of great practical importance for industrial enterprises for the purpose of steel products prompt identification. The obtained values of the carbon equivalent derived from the proposed dependence correspond to the values of the carbon equivalent calculated according to the standard GOST R 55020-2012. This method of non-destructive determination of steel grade by carbon equivalent through magnetic parameters can be applied to products made of tool and other structural steel grades.

https://doi.org/10.48081/EYMF5506

2024

Issue 3

This article examines the use of combined metal-cutting tools for performing threading operations. The main purpose of the work is to analyze the effectiveness of using these tools in terms of improving accuracy, productivity and cost-effectiveness of processing. Combined tools show significant advantages over traditional methods, including reduced processing time, improved accuracy characteristics and reduced equipment maintenance costs. The design features and principles of operation of boring threaded cutters and threaded combs, as well as their impact on production processes and the quality of final products, are considered. Threading with the use of combined metal cutting tools allows you to integrate several technological operations in one cycle, which helps to increase efficiency and reduce basing errors. Experimental data confirm that the use of comb cutters contributes to a significant increase in processing accuracy and productivity, as well as reducing the time required to perform operations. Comparative analysis has shown that combined tools provide a higher quality of the thread being cut and an extended service life compared to traditional processing methods.

https://doi.org/10.48081/GDYK4546

2024

Issue 3

The article researched the influence on the pipes mechanical properties initial billet obtained by the traditional method and the proposed method, in which the piercing process is excluded. The proposed method involves casting the initial billet for the production of seamless pipes with a cavity obtained on a continuous casting machine. The production of hotrolled seamless pipes from a hollow billet is an urgent issue today, since central porosity and axial segregation after casting are excluded, affecting the quality of the pipes obtained in the subsequent stages of production: rolling on a mandrel mill and reducing. The possibility of producing seamless hot-rolled pipes from a hollow billet is substantiated, providing the necessary set of mechanical properties that are regulated by the standards GOST 632-80, GOST 633-80 and API 5CT. The result is a minimal deviation of the mechanical properties of steel samples obtained by double deformation of a hollow continuously cast billet from samples obtained according to the traditional scheme, including the piercing process.

https://doi.org/10.48081/ICKW6203

2024

Issue 3

This study examines the quality of a gear tooth surface fragment restored through electric arc welding. Visual inspection revealed a defect-free, dense surface. Macrostructure examination displayed uniformity and absence of cracks in the metal sample. The high hardness (HRC-36.61) of the weld deposit is crucial for wear resistance, while the base metal, with lower hardness (HRC-29.09), ensures ductility and impact toughness. Martensitic and residual austenitic structures in the weld deposit indicate deformation-resistant properties, with austenite providing good ductility and martensite contributing to high hardness and strength, making the material resistant to wear and deformation under dynamic loads. Thin lens-like martensitic plates and a reed-like structure suggest unique formation characteristics during electroslag welding's oxidizing-reducing reactions. Microstructure analysis revealed a finer structure in the weld deposit compared to the base metal. The base metal exhibited a ferrite-pearlite structure typical of many steels, unchanged after welding. The weld deposit showed elevated carbon (0.70%) and manganese (1.38%) concentrations, typical for weld deposits, influencing mechanical properties. Elements like manganese and molybdenum enhance wear resistance, while the presence of chromium (0.42%) and nickel (0.12%) improves corrosion resistance, crucial in aggressive environments.

https://doi.org/10.48081/DOKO7119

2024

Issue 3

This article examines the transformative effect of China's New Energy Vehicle (NEV) initiatives, highlighting its importance in global automotive innovation and environmental sustainability. While the term NEV is exclusively associated with China, it also encompasses electric vehicles, plug-in hybrids, and hydrogen fuel cells, as a result of the country's strategic push to reduce pollution and greenhouse gas emissions. China's dominance in the NEV sector is attributed to its policies, which include substantial subsidies and tax benefits, as well as a rapidly expanding domestic market and robust infrastructure investments. The article examines the way these policies have facilitated domestic production, pushed technological advancements, and improved production efficiency. It emphasizes China's 14th Five-Year Plan, which aims to increase the market share of NEVs and develop infrastructure while aiming for carbon neutrality by 2060. The analysis suggests that other nations could be benefited by adopting similar strategies, which include government support, R&D investment, and infrastructure expansion, to create their own NEV industries. The issue of integrating foreign technology and developing local expertise is also addressed, along with potential challenges and solutions.

https://doi.org/10.48081/EZKR7918

2024

Issue 3