Development of composite materials for the manufacture of excavator buckets with increased wear resistance

Abstract

The problem of wear of working bodies of construction machinery and mechanisms remains a critical factor determining the operational characteristics and economic efficiency of earthmoving equipment. The development of composite materials for the manufacture of buckets of excavators with increased wear resistance is an urgent interdisciplinary task that requires the integration of achievements in materials science, tribology and mechanical engineering. The purpose of the research is to develop scientific and technical principles for the creation of polymer-metal composite materials with reinforcing elements for the manufacture of wear-resistant excavator buckets. The research applied methods of computer simulation of the stress-strain state, experimental tests for abrasive wear according to ASTM G65, X-ray diffraction analysis, scanning electron microscopy, as well as statistical methods of experiment planning. The empirical base of the study included 180 samples of composite materials with various types of reinforcing elements and concentrations of reinforcing phases. The results showed an increase in the wear resistance of the developed composites by 2.3-3.1 times compared with traditional Hardox 400 steel, while the coefficient of specific wear was 0.12\pm0.03~mm3/Nm for optimal composition with 15% reinforcing fibers and 8% silicon carbide nanoparticles. The bending strength reached 485\pm12 MPa, which is 47% higher than the base material. The impact strength of the composite was 28.5\pm2.1~kJ/m2, demonstrating a 35% increase relative to the control samples. The coefficient of friction has decreased to 0.28\pm0.02, which provides improved performance in conditions of intense abrasive action. The discussion of the results indicates the prospects of the developed approach for creating a new generation of wear-resistant materials that can significantly improve the efficiency of earthmoving equipment. The theoretical significance of the work lies in the establishment of patterns of structure formation and deformation behavior of multicomponent composite systems under the influence of cyclic loads and abrasive wear. The practical value is determined by the possibility of increasing the maintenance period of excavator buckets by 1.8-2.2 times, which provides a significant reduction in operating costs.