Modern research of objects of technology is largely carried out using various software systems. One of such software packages is SolidWorks. It is widely used in industrial enterprises and in research organizations. This complex has extensive libraries of properties of various structural materials. However, they do not represent the properties of all possible combinations of materials with the appropriate hardness. When building a model of a real object, it is necessary to accurately set the properties of materials. This will make it possible to carry out various design calculations with greater accuracy. Previous studies have established that the working part of the turbocharger rotor shaft (made of 40X steel) consists of two layers - surface (hardened) with a hardness of HV 530-570 and internal (not hardened). The values of the physical and mechanical properties of 40X steel with a hardness of HV 530-570 necessary for constructing a rotor shaft model are not available both in the SolidWorks material properties library and in the reference literature. To determine the necessary values of the properties of this material, a series of experiments using a bursting machine was carried out. The experiment was carried out with specially manufactured samples subjected to heat treatment to a hardness of HV 530-570. The data obtained as a result of the experiment were used to construct a model of the turbocharger rotor shaft when assigning the properties of the surface (hardened) layer. This approach makes it possible to obtain results corresponding to real details when carrying out engineering calculations of the constructed models.

Keywords: software package, model, engineering calculation, rotor shaft, surface layer, hardness, sample, tensile machine, physical and mechanical properties, repair

At present, various software systems are widely used to carry out researches in the field of technology, make it possible to create mathematical models of real objects. Their further study allows to obtain a large amount of calculated data necessary for units’ design, resource assessment and performance of the object under study. This makes it possible to significantly reduce the conduct of experimental studies of real objects, as well as to obtain additional data that characterize specific parts during operation, such as the values of internal stresses, natural vibration frequencies, data on strength, fatigue, etc. However, during the process of real objects models creating, not always all the necessary data is available. In this regard, it is necessary to carry out research with some real details. To determine the material hardness of the rotor shaft of the turbocharger at different depths from the shaft surface, special new samples were made. Next, the microhardness of the material was determined. The hardness of the material from the surface decreases and at a depth of 1 mm becomes equal to the hardness of the unhardened one. After research finishing, a geometric model of the rotor shaft is created. The model is created using the SolidWorks Simulation complex. The working part of the shaft model consists of two layers: the first one is the surface with increased hardness and 1 mm thick; the second one is internal unhardened. This model is used in the research and development of technological processes for the repair of the part.

Keywords: software package, mathematical model, static analysis, rotor shaft, hardening, hardness, sample, depth, surface layer, repair

The Minsk Motor Plant D-245 engines are the most widely used in automobiles and tractor manufacturing in Russia and neighboring countries. These engines are installed on cars of the GAZ and MAZ family, PAZ buses, special equipment manufactured by Amkodor, MTZ tractors, etc. A turbocharger is one of the engines units affects power and environmental performance. The presence of a large number of engines under consideration makes it important for repair enterprises to improve the technological process of repairing turbochargers. A large number of technologies for repair rotor shaft of the turbocharger have been developed to date. However, there is no technology to restore the outer surface of the rotor seal sleeve after they touch the hole of the middle housing. The article presents the results of calculating the stress-strain state of the rotor shaft of a turbocharger, taking into account the installation of an additional (repair) part as a turbine seal sleeve. The analysis of the created solid-state model was carried out using of the SolidWorks Simulation system. The calculation was carried out at various shaft diameters for bearings. The study found that the voltage in dangerous sections of the rotor shaft with the installed repair sleeve is higher than without it. However, they are much lower than the permissible torsional stresses. Therefore, the probability of destruction of the rotor shaft during normal operation of the turbocharger, due to the occurrence of a resonance phenomenon, even with the minimum allowable diameter, will be very small. The presented data allow the use of this repair method to restore the operability of the rotor shaft of the TKR-6 turbocharger.

Keywords: engine, turbocharger, defect, repair technology, additional part, repair sleeve, stress-strain state, solid-state model, dangerous section, permissible stress

The rotor shaft of the turbocharger is the part that determines the life of the bearing unit. Various methods of restoring the working capacity of the rotor shaft have been developed. The most common of them-treatment for repair size and applying a layer of metal coating in various ways. After that, the rotor shaft is subjected to dynamic balancing, in order to ensure the minimum allowable imbalance. Stands on the basis of microprocessor-based two-plane balancing device PB-02M are widely used in the repair industry at the present time. The article deals with the process of dynamic balancing of restored rotors. The features of this process in relation to the conditions of repair production are noted. This is a large range of repaired units and the instability of the size of the bearing surfaces after the restoration. It is necessary to adjust the balancing device for each rotor. The case in which the initial rotor imbalance is much higher than the permissible one is also considered. It is necessary to carry out balancing in several stages. Pre-balancing - this is the first stage. Then the final balancing is made to the permissible imbalance value. The article presents a general algorithm for balancing rotors on balancing stands equipped with a measuring system based on the device PB-02M. The presented approach in the application of the measurement system allows to balance the parts with the required accuracy. This will ensure a high post-repair life of the repaired unit and the whole unit.

Keywords: turbocharger, rotor, repair, restoration, machine, balancing, adjustment, unbalance, device, algorithm

The main resources are a turbocharger units are bearing unit and elements of gas oil seals. The article discusses various ways to repair and restore parts of the turbocharger. One repair method is a method of installing additional details. A review of options for its use. Identified the strengths and weaknesses are identified technological features of application. It calculates the magnitude of interference when installing doolnitelnoy, ensures reliable operation in all modes of operation of the turbocharger.

Keywords: turbocharger, more detail, bearing assembly, deterioration, defect, tightness of the sleeve bearing, average body, turbocharged, thermal distortion