This article presents a comprehensive finite element analysis (MCE) of the crusher body from three types of materials: gray cast iron (SF), polymer concrete (PB) and ABS plastic made by FDM printing. A fluid static stress analysis, a modal (frequency) analysis, and a SolidWorks Simulation thermal analysis were performed on two loads, 50 kN (soft rock) and 150 kN (granite). The results show that cast iron provides a safety factor of FOS = 9.7 @ 50KN, and polymer concrete and ABS plastic give FOS = 3.76 and 2.8, respectively. At a load of 150 kN (granite) ABS, the plastic is destroyed (FOS = 0.93 <1.0), and cast iron stores FOS = 3.2, and polymer concrete reaches FOS = 1.2. Modal analysis showed that polymer concrete has the highest natural frequency (1143.5 Hz), since the specific stiffness ratio is √ (E/ ρ). Thermal analysis showed that ABS plastic heats up to 111.8 °C and exceeds the glass transfer temperature (80-100 °C), making it thermally unusable. Cast iron is the optimal material for industrial crushers; polymer concrete is promising for laboratory installations; ABS plastic is suitable only as a demonstration material.

https://doi.org/10.48081/NiTK3.2026/132-150

2026

Issue 3

The paper examines the agglomeration of finely dispersed chromium-containing materials from ferroalloy production by stiff extrusion. The relevance of the study is associated with the growing amount of dust and sludge waste generated during metallurgical processing and the need to recycle these materials into the technological cycle without worsening smelting conditions. Direct charging of such materials into furnaces is limited by low gas permeability of the charge layer, increased dust carryover, and unstable process parameters. The aim of the work was to compare the efficiency of bentonite and polymer binders in producing BREX from chromium-containing dust and to assess the metallurgical applicability of the product. Dust from the gas-cleaning and aspiration systems of the Aktobe Ferroalloys Plant of TNC Kazchrome JSC, a member of ERG, was used as the raw material. Industrial trials were conducted at an operating extrusion site equipped with J. C. Steele and Sons machinery. Bentonite was added at 10 wt. %, while the TD 021.005.BS polymer binder was added at 2.5 wt. %. BREX quality was evaluated by geometric shape, structural integrity, and resistance to impact and abrasion according to GOST 15137-77 after 2 and 4 days of curing. The results showed that the polymer binder produced BREX with a more regular shape, better structural preservation, and higher strength characteristics than the bentonite-based samples. To assess BREX behavior under metallurgical conditions, thermodynamic modeling of high-carbon ferrochrome smelting was performed in FactSage 8.4. The calculations showed that replacing the intermediate product with BREX did not significantly affect the equilibrium composition of the metal and slag phases or the calculated slag viscosity. The results confirm the technological feasibility of using a polymer binder for stiff extrusion of chromium-containing dusts and indicate the potential of the resulting BREX for use in existing ferroalloy production under current industrial conditions.

https://doi.org/10.48081/NiTK3.2026/472-487

2026

Issue 3

The improvement of energy-intensive processes of fine grinding of materials is an important industrial problem. Currently, more than a billion tons of powders are crushed in industry, and the energy consumption for their production exceeds 20% of electricity production. In addition, as a result of wear of the grinding tools, several million tons of high-quality steels are lost annually. The quality of products in a number of industries, primarily construction, construction materials, road construction, mining, electronic, agricultural, chemical, etc., largely depends on the quality of the starting material - size, purity, grain shape, etc. Particular attention has recently been paid to the issue of the size of the starting material. This is due to the fact that the speed of processes involving substances in the solid state is proportional to the size of the surface of the particles and therefore increases sharply with increasing dispersion of powders. The object of the study is equipment for grinding production waste. The purpose of the work is to increase the efficiency of equipment for fine grinding of production and crop production waste. As a result of research, a single-module mill with a kinematic grinding device was developed and manufactured, which implements a working process of a pilot industrial sample of a 3-module mill by grinding limestone crushed stone at the 3rd stage of waste from a crushing and sorting factory. The modular design of the mill made it possible to test 3 modes of its operation. The research results are realized in a series of applications for inventions, some of which were previously recognized as inventions.

https://doi.org/10.48081/NiTK3.2026/163-181

2026

Issue 3

In this study, the optimization of hot-pressing parameters for the fabrication of the membrane electrode assembly (MEA) was carried out using RSM (Response Surface Methodology). The main parameters requiring optimization during MEA fabrication are temperature, pressure, and processing (pressing) time. Therefore, the investigated ranges of temperature, pressure, and pressing time were set at 80–130 °C, 10–100 kgf/cm², and 1–5 min, respectively. In the RSM approach, the power density was defined as the response variable to be maximized, while temperature, pressure, and pressing time were considered independent variables. This method generates a nonlinear quadratic equation based on the independent parameters. Two optimal operating conditions corresponding to the maximum power density were determined using contour plots and analysis of variance (ANOVA). Under the first optimal condition, a maximum power density of 774 mW·cm⁻² was achieved at a temperature of 98 °C, a pressure of 68 kgf/cm², and a hot-pressing time of 4.5 min. To reduce energy consumption and shorten the production time, another operating condition close to the lower limits of temperature, pressure, and hot-pressing duration was also identified, under which the maximum power density of 774 mW·cm⁻² was achieved at 89 °C and 51 kgf/cm².Furthermore, the obtained results demonstrate that effective optimization of the hot-pressing parameters can improve MEA performance while increasing the energy efficiency of the fabrication process.

https://doi.org/10.48081/NiTK3.2026/545-554

2026

Issue 3

The article presents the results of an assessment of the stability of the projected transport and technological machine, in the rear of which the Hiab 550 CMU installation is installed when lifting cargo. The purpose of the study is the scientific substantiation of the design parameters of the machine, the theoretical determination of the stability margin of the crane-manipulator installation under various operating modes and the confirmation of the results obtained by experimental studies. Since transport and technological machines are widely used in agriculture, construction and other industries, there is a high probability of overturning, damage to structural elements and other emergency situations during their operation. In this regard, a comprehensive assessment of the machine's load capacity and stability was carried out to ensure its operational safety. In the course of the study, theoretical calculations of various cargo weights, working boom radii and lifting angles were performed, taking into account the design features of the machine, mass characteristics, the location of the center of gravity and the installation scheme of the crane manipulator installation based on current regulatory and technical requirements. In order to determine the interaction of factors affecting the sustainability fund, the method of planning a multifactorial experiment was used, a matrix plan was drawn up and regression equations were obtained. Based on the obtained mathematical models, three-dimensional graphical models are constructed that describe the laws of variation of the stability margin at the working radius of the boom, the mass of the load being lifted, and the boom lifting angles of 25°, 45°, and 65°.In order to assess the reliability of theoretical calculations, field experimental tests were conducted, the results of which were compared with the calculated data. The comparative analysis showed a high correspondence between the theoretical and experimental results, which confirmed the correctness and effectiveness of the proposed calculation methodology. According to the results of the study, it was found that in the E–F operation mode, the stability indicators of the transport and technological machine exceed the regulatory requirements and the machine is safe to operate. And in the E–C operating mode, it was found that the stability margin is lower than the standard value, and in this case, the increased risk of overturning during operation of the machine and the need for additional structural or technological safety measures is justified.

https://doi.org/10.48081/NiTK3.2026/54-75

2026

Issue 3

This article presents an in-depth system analysis of the requirements for software and hardware systems used in the process of state technical inspection. It considers the issues of metrological compatibility, algorithmic assessment of expert evaluations, cybersecurity of diagnostic data, and the influence of chassis parameters on the active safety of vehicles. Particular attention is paid to harmonizing the national standards of the Republic of Kazakhstan and the Eurasian Economic Union with international directives. The article also offers a comprehensive methodological justification of technical and operational requirements for diagnostic equipment used at stations for instrumental control of vehicle condition. The relevance of the study is determined by the need to reduce anthropogenic factors in road safety systems and to increase the reliability of expert evaluations. The author proposes a characteristic decomposition of the operating criteria of the main equipment and identifies the following priorities: a high level of automation of measurement cycles, metrological control, modular hardware architecture, and cybersecurity of transmitted data. Special attention is given to intelligent inspection algorithms that automatically compare measured values with regulatory tolerance arrays in accordance with TR CU 018/2011 and international standards. The article analyzes the physics of interaction between vehicle systems and diagnostic stations and justifies the need to integrate vibroacoustic and digital testing methods. The requirements for network convergence of control computers make it possible to consider modern vehicle instrumental-control stations as elements of a unified cyber-physical system for technosphere safety monitoring. The results of the study can be used when designing new technical-inspection networks and modernizing the existing regulatory and technical framework.

https://doi.org/10.48081/NiTK3.2026/555-565

2026

Issue 3

This article addresses the issues of statistical processing and justification of measurement results obtained during the profile inspection of weld-cladded large-module gears. The main objective of the study is to determine the reliability of experimental data obtained in the evaluation of gear tooth profile geometric parameters and to validate the accuracy of measurement results using statistical methods. During the inspection process, the tooth profile coordinates were determined using a high-precision coordinate measuring method, and the obtained data were compared with calculated values derived from a mathematical model. The study analyzed the variation patterns of X, Y, and R coordinates along the profile trajectory and identified their interrelationships. To assess the differences between experimental and calculated values, residual deviations were computed and their distribution characteristics were investigated. To evaluate the stability and reliability of the measurement results, statistical indicators such as the arithmetic mean, standard deviation, coefficient of variation, and confidence interval were determined. Factors affecting the repeatability and reproducibility of the measurement results were also considered. The conducted analysis showed that the variation of coordinate parameters along the profile follows certain regular patterns. The small differences between experimental and calculated values confirm the sufficient accuracy of the applied mathematical model and measurement methodology.

https://doi.org/10.48081/NiTK3.2026/18-29

2026

Issue 3

This article presents the results of an experimental study of the weldability of HARDOX steel by manual arc welding with a consumable electrode. The research methodology is based on the following fields of science: the theory of welding processes, welding technologies and equipment, repair welding technology and hardfacing of machine parts, and the technology of metals. As a result of visual and ultrasonic analysis of the welds, it was found that, provided the optimal temperature regime is maintained (namely, the selection of the optimal current value corresponding to the thickness of the sheet being welded), it is possible to obtain a high-quality weld joint with minimal defects. However, it was also recorded that violations of the technology may cause cracks and changes in the metal structure within the weld zone. It was also established that an increase in the welding current leads to a rise in the level of the reflected sound pulse. This indicator implies embrittlement of the structure due to an increase in the volume of inhomogeneity. The volume of the reflected signal is 24% at 80 A, and 27% for the specimen welded using a current of 100 A. The data obtained confirm the need for strict control of the welding parameters and preliminary surface preparation when working with heat-resistant materials, in particular with steels of the HARDOX type, in order to maintain the proper level of mechanical properties of the material. This is especially important when they are used under conditions of high mechanical load and abrasive wear. The experimental part of the study made it possible to reveal the specific features of welding HARDOX steel, in particular the sensitivity of the material to thermal exposure and the occurrence of heat-affected zones, which can affect the strength characteristics of the weld joint.

https://doi.org/10.48081/NiTK3.2026/275-286

2026

Issue 3

The article is devoted to the design and research of a vehicle with hybrid propulsion, carried out at the Department of Transport Equipment and Logistics of the Toraighyrov University. One outcome of the work is that based on the analysis of layout schemes of such vehicles, a new practical vehicle design with a combined power unit has been proposed, with particular attention given to the battery. The article looks at ways to improve the design of batteries in vehicles with hybrid power systems. It is stated that one of the main requirements for batteries nowadays is to ensure corrosion resistance at high operating temperatures. The battery is not just a power source; it is a key part of a vehicle with a hybrid system, determining its durability, efficiency and competitiveness. The article reviews patent research and looks at different battery designs. Their main drawback is a shorter lifespan. The paper sets out and solves the problem of improving the lead-acid battery. The solution involves each cell in the lead-acid battery having a block of electrodes with opposite polarity, separated by separators and electrolyte. Based on the conducted patent research, a battery design that meets the required specifications was selected. The article describes the battery design chosen as a prototype and outlines the pros and cons of this prototype. The article presents a design for an automatic battery that significantly improves its user-friendliness, specifically by maintaining full capacity in cold weather and extending its reliable service life. The article also explains the key features of the battery's design.

https://doi.org/10.48081/NiTK3.2026/579-587

2026

Issue 3

This paper presents the results of statistical studies on the quality stabilization of beryllium semi-finished products obtained by vacuum hot pressing. The quality of hot-pressed products, as regulated by technical specifications, is primarily characterized by impurity content and physical-mechanical properties. The main unstable parameter is the ultimate tensile strength. The article examines the causes of instability in the strength characteristics of technical-grade beryllium produced by powder metallurgy under industrial manufacturing conditions. Correlation analysis revealed the primary factors determining the quality of beryllium in terms of its mechanical properties. It is shown that the silicon impurity exerts a softening effect on hot-pressed beryllium. An increase in silicon content from 0.01–0.02% to 0.02–0.03% leads to a decrease in average tensile strength values from 377 to 357 MPa and increases the rejection rate from 6% to 40%. The authors propose a mathematical model for predicting the strength properties of sintered beryllium, derived through regression analysis, which accounts for the combined influence of the chemical and physical characteristics of the powders, as well as the consolidation parameters. The model enables the determination of optimal pressing parameters, ensuring stable quality of the finished products and, consequently, a reduction in the production rejection rate.

https://doi.org/10.48081/NiTK3.2026/411-423

2026

Issue 3