Volume 04 Issue 04-2022
68
The American Journal of Engineering and Technology
(ISSN
–
2689-0984)
VOLUME
04
I
SSUE
04
Pages:
68-78
SJIF
I
MPACT
FACTOR
(2020:
5.
32
)
(2021:
5.
705
)
(2022:
6.
456
)
OCLC
–
1121105677
METADATA
IF
–
7.856
Publisher:
The USA Journals
ABSTRACT
An analysis of the performance of excavators shows that many hydraulic excavators used in mining companies
operate at a lower efficiency than those specified in the technical description. This can be caused by unforeseen
downtime, rapid failure of parts and unreliable operation of excavator workers.
This paper discusses the development of cutting elements with high service life to increase the efficiency of quarry
excavators. In addition, the results of experiments on the proposed improved denture teeth and their analysis are
presented.
KEYWORDS
Quarry, excavator, bucket, tooth, protective element, efficiency, service life, basic, improved, demolition.
Research Article
DEVELOPMENT OF A NEW DESIGN OF CUTTING ELEMENTS FOR
QUARRY EXCAVATOR BUCKETS AND RESULTS OF ITS
EXPERIMENTAL RESEARCH
Submission Date:
April 09, 2022,
Accepted Date:
April 17, 2022,
Published Date:
April 30, 2022 |
Crossref doi:
https://doi.org/10.37547/tajet/Volume04Issue04-06
Galiya Yeleubaevna Raykhanova
Republic of Uzbekistan, Tashkent region, Almalyk, Totuvlik str.
9-31, Uzbekistan
Rustam Umarhanovich Djuraev
Republic of Uzbekistan, Navoi region, Navoi, Spitamen str., 8 - 21, Uzbekistan
Sardorjon Abdumuminovich Turdiyev
Republic of Uzbekistan, Navoi region, Karmana, Bahor str., 39, Uzbekistan
Journal
Website:
https://theamericanjou
rnals.com/index.php/ta
jet
Copyright:
Original
content from this work
may be used under the
terms of the creative
commons
attributes
4.0 licence.
Volume 04 Issue 04-2022
69
The American Journal of Engineering and Technology
(ISSN
–
2689-0984)
VOLUME
04
I
SSUE
04
Pages:
68-78
SJIF
I
MPACT
FACTOR
(2020:
5.
32
)
(2021:
5.
705
)
(2022:
6.
456
)
OCLC
–
1121105677
METADATA
IF
–
7.856
Publisher:
The USA Journals
INTRODUCTION
The decrease in the operational efficiency of quarry
excavators depends on the conditions of use (physical
and mechanical properties of rocks, maintenance
conditions, etc.) and climatic conditions under the
influence of the external environment. In unfavorable
weather and difficult conditions, the freezing,
stickiness and poor quality of the rocks lead to the
rapid erosion of the cutting elements (teeth) of the
quarry excavators. This situation leads to a decrease in
the efficiency of the excavation process in exchange
for the creation of high loads on the power
mechanisms of the working members of quarry
excavators [1].
The main reason for the failure of quarry excavators
currently used in the global mining industry is the
failure of mechanical parts. The main factor in stopping
excavations and cuts due to the failure of mechanical
parts is the bucket teeth, which make direct contact
with the rock.
MATERIALS AND METHODS
Defects in the cutting elements of quarry excavators
depend on a number of factors, mainly the skills of the
excavator driver during operation, non-compliance
with service rules, adverse climatic conditions,
variability of rock properties, poorly blasted large-sized
rocks and a number of other technical factors [2].
Defects in the part of the bucket cutting element
connected to the adapter of the quarry excavator are
due to the fact that the adapter and the finger (palets)
serving to connect the cutting element are not well
tightened by service providers, special fasteners do not
fit, the fastening finger widens the hole 3].
Figure 1 shows the faults of the HITACHI EX-1200 quarry
hydraulic excavators connected to the cutting
elements and the adapter part of the bucket.
Figure 1. Defective part of HITACHI EX-1200 excavator bucket connected with cutting element and adapter part
Fault 1, shown in Figure 1, results in additional
resistance to cutting and drilling due to the fingers not
being fastened to the required standard in the
fastening part of the cutting element and the adapter
part of the bucket. In case of failure 2, due to the poor
quality of the cutting element and the adapter part, the
Volume 04 Issue 04-2022
70
The American Journal of Engineering and Technology
(ISSN
–
2689-0984)
VOLUME
04
I
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04
Pages:
68-78
SJIF
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FACTOR
(2020:
5.
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)
(2021:
5.
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)
(2022:
6.
456
)
OCLC
–
1121105677
METADATA
IF
–
7.856
Publisher:
The USA Journals
tooth is in a cold state and as a result does not sink well
into the rock [4].
In many cases, during the operation of quarry
excavators, the allowable amount of bucket cutting
elements is ignored. This can lead to tooth decay
beyond the allowable level, which can eventually lead
to tooth decay, and these defects are shown in Figure
2.
Figure 2. Perforation of HITACHI EX-1200 excavator bucket teeth due to erosion
Faults caused by untimely maintenance of teeth can
lead to malfunctions in other systems, which are even
greater. As a result of research and analysis in
production, tooth perforation also leads to rapid wear
of the adapter part, and these processes reduce the
efficiency of quarry excavators and increase operating
costs [5].
The size of the top and bottom of the excavator is
shown in Figure 3, the size of the front and the length
of the tooth L, as shown in Figure 3. studied [6].
Figure 3 Scheme for determining the amount of erosion of the teeth of the excavator bucket
The study revealed that the working time of quarry
hydraulic excavators is from 250 moto / h to 300 moto
Volume 04 Issue 04-2022
71
The American Journal of Engineering and Technology
(ISSN
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2689-0984)
VOLUME
04
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04
Pages:
68-78
SJIF
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(2020:
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)
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5.
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(2022:
6.
456
)
OCLC
–
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METADATA
IF
–
7.856
Publisher:
The USA Journals
/ h, depending on the physical and mechanical
properties of the rock, the working condition, the
quality of the explosion.
Analysis of the results of the above studies shows that
most of the faults in the teeth of quarry hydraulic
excavators used in open pit mining are not able to work
at the level required for the strength and durability of
bucket teeth, ie different types of excavated rock
quickly loses its properties when exposed to rocks, and
as a result, the teeth quickly become impenetrable,
leading to failure of other parts of the quarry
excavators and a decline in operational performance.
In view of the above, during our research work we have
made it one of our main goals to develop technical
solutions to increase the wear resistance, service life
and efficiency of the quarry excavator bucket cutting
elements [7].
It has been proved that the energy intensity of the
excavation process with collapsed cutting elements is
1.5-2 times higher than the new ones. The practice of
using excavator buckets from 3.20 to 20 m3 has shown
that the allowable erosion of the teeth increases the
specific specific shear load by 50-100% relative to the
cutting conditions with teeth of nominal shape and
size. The breakdown of the cutting elements of
excavators has a significant impact on their
performance. In some cases, due to the wear of the
working part, the productivity of the machine
decreases by up to 40% and fuel consumption increases
by up to 30% [3].
THE MAIN PART
There are several types of pit teeth of quarry hydraulic
excavators, and these teeth are used as standard
production teeth of pit hydraulic excavators used in all
open pit mines of Navoi Mining and Metallurgical
Combine ( Figures 4 and 5).
Figure 4. 3D view of standard bucket teeth
Volume 04 Issue 04-2022
72
The American Journal of Engineering and Technology
(ISSN
–
2689-0984)
VOLUME
04
I
SSUE
04
Pages:
68-78
SJIF
I
MPACT
FACTOR
(2020:
5.
32
)
(2021:
5.
705
)
(2022:
6.
456
)
OCLC
–
1121105677
METADATA
IF
–
7.856
Publisher:
The USA Journals
Figure 5. General appearance and dimensions of standard bucket teeth:
a - top view and dimensions; b - side view
and dimension
The average lifespan of this type of denture is currently
13-16 days. The time spent on each replacement leads
to a decrease in the operational efficiency of the
excavator and a long-term failure of the teeth leads to
an increase in operating costs.
Thus, to increase the productivity of quarry hydraulic
excavators, it is important to create wear-resistant
tooth
shapes, develop
and
select
effective
technological methods to increase their durability.
Theoretical research and observations of the use of
cutting elements in production have revealed the need
to increase the strength of the upper and lower
surfaces of the bucket teeth, which make the most
contact with the rock. To this end, special notches have
been created on standard bucket surfaces, and an
improved type of bucket tooth design has been
developed to increase the efficiency of quarry
excavators in order to increase their resistance to
erosion.
In this project, an improved design of the tooth in the
form of a sharp angled embossing relative to the
center of the tooth, which is slightly different from the
standard bucket teeth of quarry hydraulic excavators
(Figures 6 and 7).
Volume 04 Issue 04-2022
73
The American Journal of Engineering and Technology
(ISSN
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2689-0984)
VOLUME
04
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04
Pages:
68-78
SJIF
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FACTOR
(2020:
5.
32
)
(2021:
5.
705
)
(2022:
6.
456
)
OCLC
–
1121105677
METADATA
IF
–
7.856
Publisher:
The USA Journals
Figure 6. 3D view of advanced dentition teeth
Figure 7. Appearance and dimensions of the tooth in the form of a sharp-edged bulge relative to the center of the
improved tooth:
a - top view and dimensions; b - side view and dimensions.
EXPERIMENTAL RESULTS
In the process of making this improved bucket tooth,
special angular embossed patterns were created on
the top and bottom of the whole case. The total length
of the developed tooth is 36.0 cm. 'rtma patterns are
created.
In order to determine the effectiveness of the new
design of the developed excavator bucket teeth, they
underwent experimental tests.
During the experimental work, the abrasive abrasion
resistance of the teeth with a diamond-shaped bulge
and a sharp-edged bulge, which developed the basic
Volume 04 Issue 04-2022
74
The American Journal of Engineering and Technology
(ISSN
–
2689-0984)
VOLUME
04
I
SSUE
04
Pages:
68-78
SJIF
I
MPACT
FACTOR
(2020:
5.
32
)
(2021:
5.
705
)
(2022:
6.
456
)
OCLC
–
1121105677
METADATA
IF
–
7.856
Publisher:
The USA Journals
teeth of the excavator bucket, was studied, ie their
service life.
Experimental work was carried out in the following
stages:
In the first stage of the experimental test, with the
installation of the basic teeth on the excavator bucket,
excavation of loaded rock and semi-rock rocks with
rock strength f = 12 ÷ 14 was carried out. During the
experimental tests, the length of the bucket teeth and
the average thickness of the 5 separated parts were
determined during the operation over a period of time
(Figure 8).
z
1
, z
2
, z
3
, z
4
, z
5
– the sequence number of
sections on flat surfaces
Figure 8. Location of incisions to measure
decay rates for base teeth
In experimental tests, one of the most effective ways to determine the change in the size of the teeth of the bucket
due to friction due to friction along its length and separated parts during operation for a certain period of time is to
allow an error of Δ=0.1 mm in the differential method. was carried out using a heat-resistant ШЦ-400 barbell
compass, and these results are given in Table 1 of the applications.
Table 1
Over time, the size of the base bucket tooth changes due to friction due to friction along its length and separated
parts
T, hours
L, mm
Δl, mm
Z
1
, mm
Z
2
, mm
Z
3
, mm
Z
4
, mm
Z
5
, mm
0
360
0
40
81
103
143
174
30
332
28
33
79
102
142
173
60
308
52
-
76
100
140
171
90
286
74
70
98
137
168
120
264
96
64
95
134
165
150
249
111
-
91
131
162
180
235
125
85
128
159
210
221
139
78
124
156
240
210
150
72
119
153
270
196
164
65
114
150
300
180
180
-
108
147
Volume 04 Issue 04-2022
75
The American Journal of Engineering and Technology
(ISSN
–
2689-0984)
VOLUME
04
I
SSUE
04
Pages:
68-78
SJIF
I
MPACT
FACTOR
(2020:
5.
32
)
(2021:
5.
705
)
(2022:
6.
456
)
OCLC
–
1121105677
METADATA
IF
–
7.856
Publisher:
The USA Journals
where, T – working time of the bucket tooth, hours; L – the length of the tooth at a given time, mm; Δl – a change in
the length of a tooth over a period of time, mm; Z
1
– size on section 1, mm; Z
2
– Size on section 2, mm; Z
3
– Size on
section 3, mm; Z
4
– Size on section 4, mm; Z
5
– Size on section 5, mm.
Experimental experiments were performed on the five sharp angular embossed teeth shown in Figure 9.
The five sections shown in Figure 9 measured the amount of abrasion of sharp-edged embossed patterns
and flat surfaces over time, and the results are presented in Table 2.
Table 2
The change in the size of a five-pointed convex tooth over time due to friction due to friction along its length and
separation
T, moto-
hours
L, mm
Δl,
mm
1- cut
2- cut
3- cut
4- cut
5- cut
Z
1
mm
Z
1b
mm
Z
2
m
m
Z
2b
mm
Z
3
m
m
Z
3b
mm
Z
4
mm
Z
4b
mm
Z
5
mm
Z
5b
mm
0
360
0
35
45
76
86
98
108
138
148
169
179
30
346
14
32
38
75
85
97
107
138
147
169
179
60
329
31
28
30
74
84
96
102
137
146
168
178
90
318
42
-
-
72
82
95
98
137
146
167
177
120
306
54
70
80
94
96
135
145
166
175
150
293
67
68
78
92
94
135
142
164
173
180
286
74
65
73
90
92
132
140
162
171
210
273
93
63
65
87
89
130
138
161
169
240
248
112
-
-
84
87
128
136
159
167
270
237
123
80
82
125
134
157
165
300
226
134
76
78
121
131
156
163
330
214
146
72
74
117
126
154
160
345
203
157
68
70
114
122
152
157
360
191
169
64
66
111
111
150
151
375
180
180
-
-
108
108
147
147
where, T – working time of the bucket tooth, hours; L – the length of the tooth at a given time, mm; Δl – a change in
the length of a tooth over a period of time, mm; Z
1
– Flat surface size on section 1, mm; Z
1b
– The size of the bulge on
section 1, mm; Z
2
– Flat surface size on section 2, mm; Z
2b
– The size of the bulge on section 2, mm; Z
3
– Flat surface
size on section 3, mm; Z
3b
– The size of the bulge on section 3, mm; Z
4
– Flat surface size on section 4, mm; Z
4b
– The
size of the bulge on section 4, mm; Z
5
– Flat surface size on section 5, mm; Z
5b
– The size of the bulge on section 5,
mm.
Volume 04 Issue 04-2022
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The American Journal of Engineering and Technology
(ISSN
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2689-0984)
VOLUME
04
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Pages:
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SJIF
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(2020:
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)
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)
(2022:
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456
)
OCLC
–
1121105677
METADATA
IF
–
7.856
Publisher:
The USA Journals
z
1
, z
2
, z
3
, z
4
, z
5
– the sequence number of the flat surfaces of the cuts;
z
1b
, z
2b
, z
3b
, z
4b
, z
5b
– the sequence number in the location of the sharp corners with embossed patterns in the
sections
Figure 9. Location of cuts for measuring the amount of erosion for improved five sharp angled convex teeth
Based on the analysis of the results of experimental
tests conducted to determine the effectiveness of the
improved design of the teeth of the excavator bucket,
it was established that the service life of the bucket
teeth depends on the magnitude of fractures.
CONCLUSION
Based on the results of the experimental studies,
graphs of the dependence of the magnitude of the
erosion on the length of the service life of the basic
bucket tooth and the embossed bucket teeth with 5
sharp angular shapes were established and their a
cross-correlation graph was developed and shown in
Figure 10.
Volume 04 Issue 04-2022
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1 - basic tooth; 2 - five embossed teeth with sharp corners;
Figure 10 Graph of the corrosion rate of the basic and improved sharp-edged bucket teeth
As can be seen from the set graph of the dependence
of the magnitude of the fracture on the length of the
working life of the embossed bucket teeth with basic
and improved 5 sharp angular shapes shown in Figure
10 above, The working life of the embossed bucket
tooth, which has 5 sharp angular shapes, improved
compared to the basic bucket tooth, was found to be
75 moto-hours, or 25% more.
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Turdiyev S.A and Jurayev A.Sh 2022. Study of the
effect of excavator bucket tooth abrasion on
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Turdiyev S.A., Djurayev R.U., Jo`rayev A.Sh.
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Volume 04 Issue 04-2022
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(2022:
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OCLC
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METADATA
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–
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Publisher:
The USA Journals
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Djuraev R.U., Turdiyev S.A. Mathematical
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