Selection and Justification of the Mold Design for the ESH of Large-Module Gears

This article analyzes the choice of a mold design for electroslag surfacing (ESN) of large-modulus worn teeth. Based on the size of the worn tooth, two different mold designs have been developed that take into account the involute shape of the tooth. COMSOL Multiphysics and ANSYS software packages were used for modeling and analysis. In COMSOL Multiphysics, a simulation was performed that allows us to compare two crystallizer designs in order to select the most efficient cooling solution. As a result of the comparative analysis, the mold design was selected, which provides the necessary level of cooling during the ESH process. Then, using ANSYS, thermal stresses in the selected structure were calculated, which makes it possible to evaluate its strength characteristics and resistance to operating conditions. Thus, the work provides a theoretical and practical justification for choosing a mold design that provides.