Optimization of multi-electrode surfacing technology for freight car axle box body repair

The paper explores the impact of temperature fields on the deformation of the inner cylindrical surface of freight car axle box bodies during single and multi-electrode welding and surfacing. Flux-cored electrodes of 4 mm diameter, type UONI-13/55, were utilized at a constant arc voltage of 24 V and welding current of 320 A. Finite element modeling via ANSYS Workbench 2023 helped identify zones of maximum thermal impact, as well as temperature and deformation patterns in characteristic cross-sections.

The study found that increasing the number of electrodes during surfacing repairs lowers maximum heat input and ovality of the axle box body's inner surface. Specifically, a three-electrode surfacing technique yielded a 23.9% decrease in ovality compared to single-electrode methods, and remained below the permissible limit by 19-20%.

Experimental validation at an industrial facility using a thermal measuring station and thermocouple sensors corroborated the numerical simulations. A new device for repairing freight car axle boxes was developed and tested, demonstrating improved efficiency and reduced restoration time. The research was conducted by the Faculty of Railway Transport Engineering at Tashkent State Transport University in Tashkent, Republic of Uzbekistan, with contributions from Rustam Rahimov, Khumoyun Otajonov, and Diyor Zafarov.

The findings are licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License, requiring proper attribution and adherence to the license terms.