Experimental and statistical investigation and strength modeling of metallic cylindrical blank joints produced by resistance butt welding
Экспериментально-статистическое исследование и моделирование прочностных характеристик соединений металлических цилиндрических заготовок при контактной стыковой сварке
Yessirkepova A.B. Sherov K.T. Absadykov B.N. Sikhimbayev M.R.
2025North Caucasian Institute of Mining and Metallurgy, State Technological University
Sustainable Development of Mountain Territories
2025#17Issue 31733 - 1747 pp.
Introduction. Improving the reliability and strength of welded joints of metallic blanks is of significant industrial importance for mechanical engineering, construction, mining and transport infrastructure. The quality of resistance butt welding directly affects structural durability and operational safety. Purpose of the research. To increase the efficiency of resistance butt welding for joining cylindrical metallic blanks and to expand its technological capabilities through welding mode optimization. Materials and methods. Experimental studies were carried out on MSR-25 welding equipment using steels 40X and 45. A fractional factorial design 26–3 was implemented and a regression model was developed. Tensile tests were conducted in a certified testing center. Finite element simulation was performed in Solidworks. Results. Optimal combinations of current density, upsetting pressure and speed ensured high-quality weld formation without visible defects. Fracture during tensile testing occurred in the base metal rather than in the weld zone. The regression model was statistically adequate. Discussion. Experimental and numerical results showed good agreement. Maximum stresses were concentrated in the base metal, confirming the high strength of the welded joint. Conclusion. Resistance butt welding provides reliable joining of homogeneous and dissimilar cylindrical metallic blanks. Resume. Optimization of welding parameters enables control of mechanical properties and improves structural reliability in industrial applications. The results can be applied in manufacturing reinforcing bars and engineering structures. Future studies may focus on microstructural analysis and residual stress evaluation.
modelling , resistance butt welding , stress , tensile test , ultimate strength , welded joint
Text of the article Перейти на текст статьи
Department of Technological Equipment, Mechanical Engineering and Standardization, Abylkas Saginov Karaganda Technical University, 56, Nursultan Nazarbayev Ave., Karaganda, 100027, Kazakhstan
Department of Technological Machines and Equipment, S. Seifullin Kazak Agro-technical Research University, 62, Zhenis Ave., Astana, 010000, Kazakhstan
Academician of the RPA «National Academy of Sciences of the Republic of Kazakhstan», K.I. Satbayev Kazakh National Research Technical University, 22a, Satpayeva str., Almaty, 050000, Kazakhstan
Karaganda University of Kazpotrebsoyuz, 9, Akade micheskaya st., Karaganda, 100009, Kazakhstan
Department of Technological Equipment
Department of Technological Machines and Equipment
Academician of the RPA «National Academy of Sciences of the Republic of Kazakhstan»
Karaganda University of Kazpotrebsoyuz
10 лет помогаем публиковать статьи Международный издатель
Книга Публикация научной статьи Волощук 2026 Book Publication of a scientific article 2026