AP19174909 “Improving the quality of reinforcing bars and dissimilar cylindrical workpieces resistance butt welding by optimizing modes” – w.а. Yessirkepova A.B.
Relevance. Developing technological capabilities of the resistance butt welding method.
The project purpose is to improve the quality of resistance butt welding when connecting various metal workpieces.
Expected results
A method of resistance butt welding will be developed that which differs from the existing ones in versatility, productivity, high precision and quality of welding, as well as wide technological capabilities. A database will be developed for selecting welding mode parameters depending on the material and diameter of the metal workpieces being joined.
Domestic engineering and construction enterprises are considered as potential consumers of the proposed method of resistance butt welding.
The following results of the project will be published:
– 2 (two) articles in journals from the first three quartiles by impact factor in the Web of Science database or having a CiteScore percentile in the Scopus database of at least 50;
– an article in a peer-reviewed foreign and (or) domestic publication with a non-zero impact factor (recommended by the CCHES);
– a monograph.
Based on the results of the study, recommendations will be developed for using the resistance butt welding method to connect various metal workpieces.
The RAPID Mechanical Plant LLP directly participates as a private partner; it contributes financing in the amount of at least 0.1% of the project amount and assists in implementing the project free of charge.
A doctoral dissertation on the topic of the project will be completed by Yessirkepova A.B. and several masters’ theses.
Figure 1 – MSR-25 machine for contact butt welding and welding flow diagram (a – contact butt welding machine MSR-25; b – welding flow diagram)
Figure 2 shows process of contact butt welding of unmeasured sections of reinforcement and steel wires.
Figure 2 – The process of resistance butt welding (a – preparation for welding; b – process of butt welding; c – cooling process; d – after cooling)
Research group
- Esirkepova Aiym Bakytbekovna – scientific supervisor, M.Tech.Sci., senior lecturer of the Department of Tomography and Science, Scopus Author ID 57219115360, Researcher ID Web of Science HGD-3044-2022, ORCID 0000-0003-4524-5135.
https://www.scopus.com/authid/detail.uri?authorId=57219115360
- Sherov Karibek Tagaevich – scientific consultant, Doctor of Technical Sciences, Professor of the Department of Technical and Technical Sciences, KazATU. Scopus Author ID 55330253200, ORCID 0000-0003-0209-180X.
https://www.scopus.com/authid/detail.uri?authorId=55330253200
List of publications:
- Esirkepova A.B., Sherov K.T., Akhmedov Kh.I. The problem of increasing the efficiency of joint welding of reinforcement. Materials of the international scientific and practical conference “XV Saginov Readings. Integration of education, science and production”, Part 3. – Karaganda: Publishing House of KarSTU, 2023. – P.164-166. https://www.kstu.kz/wp-content/uploads/2023/06/Sbornik-2023-CHast-3
Expected publications:
– 2 articles in the first three quartiles of the impact factor in the Web of Science database or in journals with at least the 50th percentile of CiteScore in the Scopus database;
– 1 article in journals and (or) other peer-reviewed domestic peer-reviewed scientific publications.
Scope of application: Mechanical engineering and construction industry.
AP19175058 “Numerical modeling of cutting processes for difficult-to-cut materials in the conditions of machine building enterprises of the Republic of Kazakhstan” – n.r. Donenbaev B.S
Relevance
Mechanical treatment remains the main type of parts shaping. High requirements for accuracy, roughness and surface quality pose the need to improve machining technology and production preparation, especially when machining parts made of difficult-to-machine materials at engineering enterprises of the Republic of Kazakhstan. Difficult-to-machine materials include large parts and modern wear-resistant materials.
In the domestic industry, the following factories specialize in manufacturing and restoring large-sized parts: the Almaty Heavy Engineering Plant JSC (AZTM) and the Petropavlovsk Heavy Engineering Plant JSC (PZTM).
In order to study the problems associated with manufacturing large-sized parts, a study was conducted in the conditions of the “AZTM” JSC.
As a result of the study, the state of issues related to machining technology and ensuring the quality indicators of large-sized parts in the conditions of the “AZTM” JSC, a number of problems were identified: the time spent for mounting, alignment, fastening and removal of large-sized parts; the need to manufacture additional equipment; the occurrence of vibrations that negatively affect the machining accuracy and the durability of the cutting tool, leading to high consumption of the cutting tool.
When machining modern materials, selecting the parameters of machining modes becomes additionally complicated due to their absence.
The efficiency of machining difficult-to-machine materials can be increased by numerical simulation of machining processes in software packages for engineering calculations. This requires the development of a new methodology of modeling machining processes. The development of such a technique makes it possible to obtain the data of deformations, stresses, temperatures, and distribution of cutting force values in the machining zone.
The analysis of the results obtained makes it possible to select optimal cutting conditions and tool geometry from the point of view of increasing tool life and the quality of the machined surface.
The practical significance of the results of this study will be directly applied to solve current problems of socio-economic and scientific and technical development of domestic engineering enterprises of the Republic of Kazakhstan.
The project purpose
The purpose of the project is to increase the tool service life and the quality of the machined surface of difficult-to-cut materials.
Expected and achieved results
A method of numerical modeling of the machining difficult-to-cut materials will be developed to determine favorable cutting conditions for various methods (milling, turning, drilling, etc.) of machining, as well as a method of developing a model of the destruction of difficult-to-cut materials for software systems.
The following results of the project will be published:
– 2 (two) articles in journals from the first three quartiles by impact factor in the Web of Science database or having a CiteScore percentile in the Scopus database of at least 50;
– 2 (two) articles and (or) reviews in peer-reviewed foreign and (or) domestic publications recommended by the CCHES;
– 1 certificate of state registration of rights to the object of copyright.
Based on the results of the study, recommendations will be developed for machining difficult-to-cut materials using various methods (milling, turning, drilling, etc.) of mechanical treatment, as well as selecting the cutting modes.
Direct participation as a private partner is taken by the STEP Design Bureau LLP, which contributes financing in monetary terms in the amount of 1% of the project amount.
The developed methods have scientific and practical value for the mechanical treatment industry, as well as for specialists involved in the development of software systems.
Based on comparative analyzes of experimental and numerical results of the destruction of carbon steel, an article was published in the third issue of the series Technical Sciences and Technologies of the Bulletin of the L.N. Gumilyov Eurasian National University recommended by the CCHES on the topic “Experimental studying and numerical modeling of the stage of low-carbon steel development stage of destruction”.
Research team
- Donenbayev Bakytzhan Serikovich – Scientific Supervisor, PhD, Senior Lecturer of the Department of Mechanics
Hirsha Index – 2, ResearcherID – С.
https://orcid.org/0000-0001-6923-3476
- Magavin Sabit Shamilyevich – researcher, PhD, Associate Professor of the Department of Mechanical and Physical Education of NJSC “Saken Seifullin Kazakh Agrotechnical University”
Hirsha Index – 2, ResearcherID: FMW-5410-2022,
https://orcid.org/0000-0003-0920-1442 ,
List of publications:
- S. Donenbayev, S.Sh. Magavin, K.T. Sherov, A.K. Rakishev, M.M. Mussayev. Experimental study and numerical modeling of the development stage of low-carbon steel destruction // L.N. Herald of Gumilev National University. Technical Sciences and Technology Series. No. 3/2023. – p. 134-142.
Information for potential consumers
This project will consider the analytical calculation of cutting conditions for hard-to-cut materials during various mechanical operations, taking into account the results of experimental and numerical finite element modeling of the machining process. The optimal cutting conditions for various machining methods will be determined.
The practical significance of the results of this study is directly applicable to solving current problems of socio-economic and scientific and technical development of domestic machine-building enterprises of the Republic of Kazakhstan.
The developed methodologies have scientific and practical value for the field of mechanical treatment and mechanical engineering, as well as for specialists in the development of software systems.
Scope
Machine building enterprises of the Republic of Kazakhstan.
AP19175311 “Increasing energy efficiency and reliability of centralized heat supply based on optimization of thermal insulation parameters”, p.m. Baidussenov G.N.
Relevance
Improving methods of optimizing the calculation of thermal protection of pipelines and equipment and substantiating the methodology of selecting thermal insulation materials to improve the performance characteristics and efficiency indicators of heating networks with the development of the necessary software.
Heating networks account for a large share of wear and tear and, as a result, financial costs. Reducing coolant losses and its energy potential, increasing the service life of CHS systems through the use of modern pre-insulated pipes and annual monitoring of their condition will make it possible to rationally use the country’s energy potential and reduce heat tariffs. Therefore, the analysis of thermal insulation materials that contribute to the efficient and long-term operation of heating networks is an urgent task in the development of heat supply systems:
1) reliability of the existing calculation methods of determining heat losses will be assessed based on an analysis of actual data of the materials, structures, the state of thermal insulation and heat loss values under various operating conditions;
2) a methodology will be developed for determining normalized heat losses, which will allow calculating specific heat losses under different conditions for laying heating networks, taking into account a larger number of operating and design parameters;
3) a methodology will be developed to determine the optimal values of the parameters of thermal insulation made of polyurethane foam and TEKHMAT pipelines when designing heating networks that provide minimal heat losses and ensure energy-efficient technical and economic indicators of the heating network;
4) effective calculation programs and algorithms will be developed to predict the magnitude of heat losses of underground heating mains at the design stage, ensuring normal operation of the heating network and preventing destruction of the insulating and covering layer on the supply and return pipelines, flooding of the channel with network water, and moistening of the soil around the heating pipeline;
5) the possibilities of reducing heat loss standards to specific values for modern insulating materials (PUF and TEKHMAT) will be identified and scientifically substantiated;
6) methods will be developed to save energy during the transfer of thermal energy by reducing heat loss through the thermal insulation of pipelines using a thin-film coating on the surface of the existing traditional insulation.
The project purpose
The purpose of the project is to improve methods for optimizing the calculation of thermal protection of pipelines and equipment and to substantiate the methodology for selecting thermal insulation materials to improve the operational characteristics and efficiency indicators of heating networks with the development of the necessary software.
Expected and achieved results
1) reliability of existing calculation methods for determining heat losses will be assessed based on an analysis of actual data on materials, structures, the state of thermal insulation and heat loss values under various operating conditions;
2) a methodology will be developed for determining normalized heat losses, which will allow calculating specific heat losses under different conditions for laying heating networks, taking into account a larger number of operating and design parameters;
3) a methodology will be developed for determining the optimal values of the parameters of thermal insulation made of polyurethane foam and TEKHMAT pipelines when designing heating networks that allow minimal heat losses and ensure energy-efficient technical and economic indicators of the heating network;
4) effective calculation programs and algorithms will be developed to predict the magnitude of heat losses of underground heating mains at the design stage, ensuring normal operation of the heating network and preventing destruction of the insulating and covering layer on the supply and return pipelines, flooding of the channel with network water, and moistening of the soil around the heating pipeline;
5) the possibilities of reducing heat loss standards to specific values for modern insulating materials (PUF and TEKHMAT) will be identified and scientifically substantiated;
6) methods will be developed to save energy during the transfer of thermal energy by reducing heat loss through the thermal insulation of pipelines using a thin-film coating on the surface of the existing traditional insulation.
Figure 1 shows the appearance of a laboratory test bench for studying the thermal engineering of liquids, which includes a pipeline with thermal insulation.
 |
Figure 1. Appearance of the laboratory test bench for studying the thermal engineering of liquids that includes a pipeline with thermal insulation |
Research team
- Baydyussenov Galym Nurzhanovich, project manager, MS, senior lecturer of the ES Department.
H-index 0
ORCID: 0000-0001-6145-7117
Scopus Author ID: 57541025100
Researcher ID: HGD-2613-2022
- Abildinova Saule Kianbekovna, scientific consultant, PhD, Associate Professor of the MiPI Department, Gumarbek Daukeyev Almaty University of Energy and Communications NJSC.
H-index 3
ORCID: 0000-0002-9502-6208,
Scopus Author ID: 57192198775
Researcher ID: CCO-6276-2022
Future publications
- Implementation of new methods for calculating heat loss under humidification of a heat insulator. Applied Sciences (Switzerland), Crystals, MDPI edition.
Information for potential consumers
Improving methods of optimizing the calculation of thermal protection of pipelines and equipment and substantiating the methodology of selecting thermal insulation materials to improve the performance characteristics and efficiency indicators of heating networks with the development of the necessary software.
Heating networks account for a large share of wear and tear and, as a result, financial costs. Reducing coolant losses and its energy potential, increasing the service life of DH systems through the use of modern pre-insulated pipes and annual monitoring of their condition will make it possible to rationally use the country’s energy potential and reduce heat tariffs. Therefore, the analysis of thermal insulation materials that contribute to the efficient and long-term operation of heating networks is an urgent task in the development of heat supply systems.
The study focuses on improving thermal insulation in a district heating network. The strengths of the proposal are the high relevance of the topic, that is, energy efficiency and energy infrastructure design. Thus, the proposed topic is of great interest for Kazakhstan. Interesting and in-demand applied research in the field of energy and mechanical engineering, – project goals and research plan are clear and realistic, – good infrastructure
A series of controlled laboratory experiments will be conducted to study configuration and energy loss.
Scope
The project is interdisciplinary; an interdisciplinary approach is assumed in terms of interaction between narrow scientific fields. The project is relevant both for the construction engineering sector and for the mechanical engineering and energy sectors. Therefore, the proposal is highly rated as it demonstrates interdisciplinary and highly innovative objectives.
AP19174774 “Studying the impact of underground mining on surface social objects”, p.m. Khuangan N.
Relevance
Ore mining with the use of the room-and-pillar system is one of the most efficient systems. Significant disadvantages of the technology used are the loss of ore in the pillars left to support the mined-out space (voids), the accumulation of the volume of voids and their collapse after the destruction of the pillars due to a long service life (decades). Sudden collapses of mined-out spaces over large areas are accompanied by man-made earthquakes.
In 1996, after a series of major collapses accompanied by earthquakes, a new Concept for the further effective and safe development of the Zhezkazgan deposit in the current mining and geomechanical conditions was developed and agreed upon with the State Mining and safety Organization (GGTN) Committee of the Republic of Kazakhstan and approved by the Minister of Industry and Trade of the Republic of Kazakhstan. It fixed three fundamental provisions, in accordance with which the industrial exploitation of the deposit will be completed: 1) the completion of the remaining balance reserves should be carried out using a room-and-pillar system, for which, in the conditions of Zhezkazgan, there is no acceptable alternative for the extraction of ore of ordinary and lower value; 2) simultaneously with the primary development of the remaining balance reserves, re-development of previously abandoned pillars with the return of ore from losses; 3) in the course of repeated development, eliminate accumulated voids by controlled self-collapse of the overlying strata.
The impact of underground mining during the development of ore bodies and/or left inter-chamber pillars on the deformation of the earth’s surface with buildings is studied by numerical modeling of the stress-strain state of the massif using finite element methods with the COMSOL and MATLAB application packages that were developed specifically for engineering and scientific research, including that in the field of geomechanics.
To assess the impact of underground mining on the stability of protected objects, absolute (mm) and relative (mm/m) subsidence of the surface of the displacement trough are used.
Calculations of the displacement of the rock massif and numerical modeling of the geomechanical state of the undermined areas of the day surface along profile lines will give the values of vertical subsidence. This is a conclusion about possible serious deformations of surface objects falling into the displacement zone, and, accordingly, about the need to resettle residents of the villages of Zhezkazgan and Krestovsky to a safe place.
The project purpose
The purpose of the project is to carry out calculations of the geomechanical parameters of the displacement of the rock mass and numerical modeling of the geomechanical state of the undermined sections of the day surface along three profile lines showing the values of the absolute vertical subsidence of the day surface. This allows us to draw a conclusion about possible serious deformations of surface objects falling into the displacement zone.
Expected and achieved results
As a result of implementing the project, a methodology will be developed to assess the impact of mining operations on the condition of surface protected objects. The methodology is implemented using application programs on a PC and includes the procedure for modeling geomechanical processes, assessing the stress-strain state of a rock mass, calculating displacements and subsidence of the surface within the displacement trough.
The methodology will allow technical services of mining organizations to optimize the procedure for carrying out mining operations in terms of their planning, taking into account the time factor.
- At least 2 (two) articles will be published in journals from the first three quartiles by impact factor in the Web of Science database or having a CiteScore percentile in the Scopus database of at least 50.
- At least 2 (two) articles and/or reviews will be published in peer-reviewed foreign and/or domestic publications recommended by the CCHES.
- It is planned to obtain 2 (two) certificates of entering information into the state register of rights to objects protected by copyright.
A numerical method was carried out to predict the magnitude of man-made earthquakes during underground mining in the conditions of the Zhezkazgan ore deposit:
According to scientists Mosyakin D.V. and Makarov A.B., the dependence of the energy class of an earthquake on the area of collapse was obtained (Figure 1).
A graph of the relationship between the displacement of the massif during collapse and the magnitude of the man-made earthquake was constructed. its view is shown in Figure 2.
The numerical modeling of the stress-strain state of the massif along profile line No. 32 of mine No. 31 VZhR showed vertical subsidence of the trough, shown in Figure 3.
Calculated using the formula M = 4,851 · L0,268, the magnitude of the man-made earthquake caused by the vertical subsidence of the massif equal to 0.45 m is 3.95.
Figure 4 shows a design diagram for numerical modeling of stress-strain state using the finite element method along profile line No. 21 of the same mine No. 31 VZhR.Рисунок 3 – График абсолютных вертикальных оседаний (мм) поверхности мульды
It can be seen from the Figure that three deposits are completely removed, which can lead to large displacements of the massif and a significant man-made earthquake.
Research team
- Khuaangan Nurbol, project manager, PhD in Mining Engineering, Ass. Professor, Head of the Methane Energy Testing Laboratory.
H-index-3, https://www.scopus.com/authid/detail.uri?authorId=57191875943, https://orcid.org/my-orcid Author ID in Scopus: 57191875943 ORCID ID: 0000-0001-9609 -6649
- Assainov Sergey Tursunovich, scientific consultant, PhD, senior lecturer of the MDD Department.
List of publications
An article in a journal included in the CCHES database (Khuangan Nurbol, Assainov Sergey Tursunovich, Shakhatova Aliya Talgatovna. “Geomechanical assessment of the impact of mining an excavation site on the condition of underground geomechanical structures”. University Proceedings. No. 3 (92) 2023, Section “Geotechnologies. Life Safety”. P. 213-219. DOI 10.52209/1609-1825_2023_3_213,).
A certificate of state registration of intellectual property rights was received (Certificate of entering information into the state register of rights to objects protected by copyright No. 39404 dated October 4, 2023 (authors: Khuangan Nurbol, Assainov Sergey Tursunovich).
Information for potential consumers
An analytical report has been compiled based on the results of geotechnological research to study physical and mechanical properties and structural features of the rock massif and given a brief geological characteristic of the Zhezkazganskoe deposit.
A database of physical and mechanical properties of ore bodies and enclosing rocks has been compiled; the was described the impact of mining, geological and mining-technical conditions of the deposit on the parameters of underground mining during the development of ore bodies.
The obtained research results will allow drawing informed conclusions about the possibility or impossibility of underground mining in specific areas of the deposit.
Scope
Mining enterprises that develop minerals using the underground method.