Substantiation and process design to manufacture polymer-concrete transfer cases for mining machines

Leonid Krupnik¹, Kasym Yelemessov¹, Baurzhan Beisenov¹, Dinara Baskanbayeva¹

¹Institute of Metallurgy and Industrial Engineering, Satbayev University, Almaty, 50013, Kazakhstan

Min. miner. depos. 2020, 14(2):103-109

https://doi.org/10.33271/mining14.02.103

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      ABSTRACT

      Purpose. To determine efficient polymer-concrete composition and to develop a process design to use the material to manufacture transfer cases for mining machines operating under very heavy conditions to improve their strength, durability, and operational economy.

      Methods. Compositions of polymer-concrete being tested have been applied to manufacture models being the bars with 40×40 section and 160 mm length. The models were produced by series in threes by means of the mixture placing in the special metal moulds. A sample of the polymer-concrete mixture to manufacture the models was taken from the central share of the batch. The polymer-concrete mixture was placed and compacted within the moulds in accordance with the regulatory requirements. To accelerate solidification, the models were warmed-up in a drier at 80°C temperature. Strength tests of the solidified models were performed using hydraulic press PGM-50MG4 according to regulatory requirements.

      Findings. Technological capability and expediency of the polymer concrete use to manufacture transfer cases operating under heavy conditions have been identified. The material has a number of advantages: less weight of the product, high strength and resistance to corrosive media. Methods of the efficient portioning of such a polymer-concrete mixture have been developed; stress-strain properties of the mixture after solidification have been defined; effect of rotational speed of the mixer effector and mixing time on the production of the mixer having homogenous characteristics. Transfer case TS-250 has been manufactured and tested which demonstrated positive results.

      Originality.New regularities of the effect of temperature of initial components, rotational speed of the mixer effector, and plastifier consumption on the polymeric-concrete mixture have been identified. The abovementioned is required for the development of efficient method to manufacture transfer case components.

      Practical implications.Optimum composition of polymeric-concrete mixture has been developed; parameters of the method and operation modes of mixture formation and transfer component casting have been tested. Such castings of transfer cases were produced which supported performance capabilities and efficiency of the process solutions.

      Keywords: polymer concrete, transfer case, aggregate, resin, hardener, rotational speed, silagerm, casting, homogenous mixture, isotropic material

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