Ways to change the design of the fastener to increase the strength of the “tungsten carbide insert cutter – cone” connection for roller cone bits
Students Name: Ivakhnenko Ihor Andriiovych
Qualification Level: magister
Speciality: Manufacturing Engineering
Institute: Institute of Mechanical Engineering and Transport
Mode of Study: full
Academic Year: 2023-2024 н.р.
Language of Defence: ukrainian
Abstract: This Master’s thesis contains scientific research and the results of the development of a technological process for the manufacture of a part. The research consisted of developing an optimum design of a carbide rock cutting tooth insert to ensure a reliable connection with the body of a drill bit. The main requirement was an optimum distribution of contact stresses in the carbide tooth - sleeve - bit body mating surfaces. In addition, the best possible rigidity of the carbide tooth was ensured by selecting rational design parameters based on analysis. The design also took into account the requirements for manufacturability of the insert rock-breaking equipment for drill bits, in particular ease of maintenance and high production efficiency. In the first section, a literature review is carried out on the subject of scientific research. Based on the results obtained, a new design of the tooth fixation in the cutter is designed. This improved model of the rock-breaking insert shows what reasonable changes have been made. In order to carry out a comparative analysis of the stress states in the cross-sections of the cutters, 3D models of two designs were constructed: the developed rock-breaking tool and the standard version using conventional rock-breaking teeth with cylindrical shanks. It was found that the proposed design of the "combined tooth-ring-shot" connection is characterised by a higher service life and, accordingly, higher efficiency of the rock-breaking equipment. The second section describes the analysis of the intended use of the product and the development of the product design for manufacturability. The product is a fan pulley. The output programme for the task is 1800 units. In this section, the technological process of product manufacture is developed, the design of the part is tested for manufacturability, which is one of the important factors in ensuring a high level of technological preparation for the manufacture of a new product. An important part of this section is to determine the method of obtaining the part. After the technical and economic calculations, it was determined that sand casting with machine moulding was the more rational method of obtaining the part. In the SolidCAM environment, all the settings were made to write a programme in the Fanuc language. In the third chapter, two devices were designed and calculated (a clamping device for vertical milling and a control device for measuring the concentricity). In the fourth section, economic calculations were carried out to determine the cost of the scientific research and the cost to the end user. As a result of the calculations, the economic feasibility of developing a new tooth design and introducing changes to the drilling tool manufacturing process was demonstrated. The explanatory note contains the main calculations, tables to present the results of similar calculations for clarity and ease of comparison, and graphical illustrations to explain the text of the thesis. The note is accompanied by appendices containing route and operational maps, sketch maps and a CNC program. Keywords: Combined tooth, SolidCAM, workpiece, manufacturability, equipment, tool, design and technological tasks, allowance, roller cutter, cutting modes.