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Theoretical analysis of passive rail grinding 钢轨被动磨削的理论分析
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2022-09-15 DOI: 10.17212/1994-6309-2022-24.3-22-39
A. Ilinykh, V. Banul, D. Vorontsov
Introduction. There are different rail machining technologies designed to eliminate defects on the tread surface and extend the life cycle of rails. The most used is the technology of grinding rails with rotating grinding wheels using rail-grinding trains. Its main disadvantage is the low working speed of the grinding train that requires the organization of track possessions with stopping the movement of trains along the haul. To perform preventive rail grinding with minimal metal removal from the rail head, passive grinding technologies using grinding wheels have become widespread in last years. Passive grinding is when there is no power on the grinding wheel to rotate it actively. Such methods make it possible to achieve high speeds of the grinding train, and the work can be carried out in the train schedule without closing the stage. Currently, passive grinding technologies are relatively new and do not have the necessary scientific basis for optimizing the machining process. The aim of the work is to perform theoretical studies of kinematic and force analyzes of two methods of rail passive grinding: the periphery and the end face of the grinding wheel. Methodology of the work is kinematic and power calculations of rail grinding schemes. Results and discussion. Within the framework of theoretical studies, a kinematic and force analysis of two methods of passive grinding are carried out, on the basis of which the optimal conditions for its implementation are determined. It is established that the method of passive grinding by the periphery of the wheel has a 20 % higher productivity and energy efficiency of the process before end passive grinding due to the higher rotation speed of the grinding wheel with equal forces of pressing it to the rail. At the same time, passive grinding with the end of the wheel is distinguished by a twice greater range of change in both the speed of the grinding wheel rotation and the force of its pressing that makes it possible to achieve greater metal removal at equal speeds of the grinding trains. In conclusion, promising tasks for further research in the field of passive rail grinding are formulated.
介绍有不同的钢轨加工技术旨在消除踏面上的缺陷,延长钢轨的使用寿命。最常用的是使用钢轨打磨列车用旋转砂轮打磨钢轨的技术。其主要缺点是研磨列车的工作速度低,需要组织轨道占用,同时停止列车沿运输路线的移动。为了在轨头金属去除量最小的情况下进行预防性钢轨磨削,近年来,使用砂轮的被动磨削技术已经广泛应用。被动研磨是指砂轮上没有动力主动旋转的情况。这样的方法可以实现研磨列车的高速,并且可以在不关闭阶段的情况下在列车时刻表中进行工作。目前,被动磨削技术相对较新,不具备优化加工工艺的必要科学依据。本工作的目的是对钢轨被动磨削的两种方法:砂轮的外周面和端面进行运动学和力分析的理论研究。工作方法是轨道磨削方案的运动学和功率计算。结果和讨论。在理论研究的框架内,对两种被动磨削方法进行了运动学和力分析,并在此基础上确定了实施被动磨削的最佳条件。已经确定,通过砂轮周边进行被动磨削的方法在端部被动磨削之前具有20%的生产率和能源效率,这是由于砂轮在将其压到轨道上的力相等的情况下具有更高的转速。同时,用砂轮末端进行被动磨削的区别在于砂轮旋转速度和挤压力的变化范围大两倍,这使得可以在相同的磨削速度下实现更大的金属去除。总之,提出了在被动钢轨磨削领域进一步研究的有希望的任务。
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引用次数: 1
Electrospark deposition of chromium diboride powder on stainless steel AISI 304 二硼化铬粉末在AISI 304不锈钢上的电火花沉积
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2022-06-15 DOI: 10.17212/1994-6309-2022-24.2-78-90
A. Burkov, M. Kulik, Alexander Belya, V. Krutikova
Introduction. Austenitic stainless steel AISI 304 is the most widely used type of stainless steel. However, it is subject to wear due to relatively low hardness, and also begins to oxidize intensively in air at a temperature above 800 °C. The use of coatings based on chromium boride can improve its tribotechnical properties and oxidation resistance. The purpose of the work: to study the effect of chromium diboride concentration in the anode mixture on the structure, wear behavior, oxidation resistance and corrosion properties of electric spark coatings on AISI 304 steel. The research methods. Electric spark treatment of AISI 304 steel was carried out in a mixture of iron granules with the addition of CrB2 powder in amount of 5, 10 and 15 vol.%. The structure of the coatings was studied by X-ray analysis, scanning electron microscopy, and electron dispersion spectroscopy analysis. The wear resistance of the coatings was studied under dry friction condition at a load of 10 N. The oxidation resistance test was carried out at a temperature of 900 °C for 100 hours. Results and Discussion. According to X-ray analysis, it is shown that under the conditions of electric spark exposure, CrB2 interacts with iron melt; this has resulted in the formation of chromium and iron borides. Corrosion properties, microhardness, coefficient of friction and wear are investigated in comparison with AISI 304 steel. Samples with coatings showed a lower corrosion potential and corrosion current density compared to the substrate in 3.5% NaCl solution and from 5 to 15 times higher oxidation resistance. The microhardness of the coatings increased from 6.25 to 7.60 GPa with an increase in the addition of chromium diboride in the electrode mixture. The coefficient of friction and the wear rate of all coatings were lower than that of AISI 304 stainless steel, while the coating prepared with the addition of 5 vol.% chromium diboride had the best tribotechnical characteristics.
介绍奥氏体不锈钢AISI 304是使用最广泛的不锈钢类型。然而,由于硬度相对较低,它会受到磨损,并且在800°C以上的空气中也会开始剧烈氧化。使用基于硼化铬的涂层可以提高其摩擦学性能和抗氧化性。本工作的目的:研究阳极混合物中二硼化铬浓度对AISI 304钢电火花涂层结构、磨损行为、抗氧化性和腐蚀性能的影响。研究方法。在铁颗粒的混合物中对AISI 304钢进行电火花处理,并添加5、10和15体积%的CrB2粉末。通过X射线分析、扫描电子显微镜和电子分散光谱分析研究了涂层的结构。在干摩擦条件下,在10N的载荷下研究了涂层的耐磨性。在900°C的温度下进行了100小时的抗氧化试验。结果和讨论。X射线分析表明,在电火花暴露条件下,CrB2与铁熔体相互作用;这导致了铬和铁硼化物的形成。通过与AISI 304钢的对比,研究了其腐蚀性能、显微硬度、摩擦系数和磨损性能。与在3.5%NaCl溶液中的基材相比,具有涂层的样品显示出更低的腐蚀电位和腐蚀电流密度,并且抗氧化性高出5-15倍。随着电极混合物中二硼化铬的加入,涂层的显微硬度从6.25GPa提高到7.60GPa。所有涂层的摩擦系数和磨损率都低于AISI 304不锈钢,而添加5体积%二硼化铬制备的涂层具有最佳的摩擦学性能。
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引用次数: 0
Deformations in the nonstationary stage of aluminum alloy rod extrusion process with a low elongation ratio 低伸长率铝合金棒材挤压过程非平稳阶段的变形
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2022-06-15 DOI: 10.17212/1994-6309-2022-24.2-39-49
Y. Loginov, G. Shimov, N. Bushueva
Introduction. It is noted that extrusion is the main procurement process in the aluminum alloys forming operations. At the same time, the process has such a disadvantage as the nonstationarity of the metal plastic flow. The work aim is to establish the inhomogeneity deformation level of the pressed rod front part by numerical simulation using the finite element method. The study objectives are to formulate the extrusion process boundary conditions, to obtain a solution and to evaluate the inhomogeneity degree. Research methods: the finite element method was used to evaluate the deformed state. The actions sequence included the creation of primary deformation zone shape and the tool configuration. The mutual movement of the tool and the deformable material is set using the appropriate boundary conditions. The deformable medium is a ductile material with power-law hardening, the physical and mechanical properties correspond to the aluminum alloy of the 6000 series. Results and discussion: It is revealed that the strain degree in the pressed rod front part is extremely nonuniform distributed; differences above 300% are recorded. The strain degree distribution dependences in the rod cross sections are constructed depending on the distance from the front end at different relative radial coordinates. It is revealed that the rod central layers acquire a constant level of the strain degree earlier than the peripheral layers. The stationary process is achieved with less metal motion. The work result application scope is the technological study of rational metal cutting of aluminum alloys at the extrusion final stage in order to use recyclable waste more rationally. Conclusions. In the extrusion process with a low elongation ratio, the strain degree is distributed nonuniform both along the press rod cross and along its length. The rod front part remains weakly deformed both at the periphery and in the center in the nonstationary initial extrusion stage. It often forces to send for remelting due to the insufficiently developed metal structure. At the same time, if the limits on the minimum possible degree of deformation are set, then using the results of the calculation by the finite element method, the minimum length of the metal to be removed can be set, thereby reducing the mass of waste sent for remelting.
介绍值得注意的是,挤压是铝合金成型操作中的主要采购过程。同时,该工艺存在金属塑性流动不稳定等缺点。本工作的目的是通过有限元方法进行数值模拟,建立压杆前部的不均匀变形水平。研究目的是制定挤压过程的边界条件,获得解并评估不均匀度。研究方法:采用有限元法对变形状态进行评估。动作序列包括创建主变形区形状和工具配置。使用适当的边界条件来设置工具和可变形材料的相互移动。可变形介质是一种具有幂律硬化的韧性材料,其物理力学性能与6000系列铝合金相当。结果与讨论:压杆前部的应变程度分布极不均匀;记录了300%以上的差异。在不同的相对径向坐标下,杆截面中的应变度分布依赖于与前端的距离。结果表明,杆中心层比外围层更早地获得恒定水平的应变程度。固定过程是用较少的金属运动来实现的。工作成果应用范围是对铝合金挤压成型最后阶段进行合理金属切削的技术研究,以便更合理地利用可回收的废料。结论。在低伸长率的挤压过程中,应变速率沿压杆的横截面和长度分布都不均匀。在非平稳初始挤压阶段,杆前部在外围和中心都保持微弱变形。由于金属结构不够发达,它经常被迫进行重熔。同时,如果设定了最小可能变形程度的限制,那么利用有限元法的计算结果,可以设定要去除的金属的最小长度,从而减少被送往重熔的废物的质量。
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引用次数: 1
Theoretical simulation of the process interelectrode space flushing during copy-piercing EDM of products made of polymer composite materials 高分子复合材料制品复制穿孔式电火花加工中电极间隙冲洗过程的理论模拟
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2022-06-15 DOI: 10.17212/1994-6309-2022-24.2-25-38
E. Shlykov, Timir Ablyaz, K. Muratov
Introduction. Polymer composite materials (PCM) are used to improve the mechanical properties and increase the working period of products. For the processing of products made of PCM, the use of electrophysical processing methods is standard. One of these methods is copy-piercing electrical discharge machining (EDM). The use of such methods for processing PCM is due to its high physical and mechanical characteristics and the complexity of processing by blade methods. Considering the fact that the PCM element is a binder – epoxy resin, which is destroyed at the edges of the resulting holes and grooves during EDM, PCM can be considered difficult to process. During the EDM of holes in PCM products, the temperature rises, and inefficient cooling often occurs in the processing zone. The paper is devoted to theoretical simulation in the Ansys package, which makes it possible to evaluate the impact of flushing method on the efficiency of the EDM of PCM products based on numerical simulation in finite element analysis software systems. The aim of the work is to increase the productivity of the processes of EDM for PCM products. Methods. Experimental studies were carried out according to the method of a classical experiment on a copy-piercing electrical discharge Smart CNC machine. The workpiece was processed at a constant voltage U = 50 V, pulse on-time Ton = 100 µs and current: I = 10 A. For theoretical simulation of the flow, the ANSYS CFX 20.1 software was used. Flow distribution simulation was carried out at three processing depths (2 mm, 10 mm, 15 mm), as well as at three nozzle inclination angles (15°, 45°, 75°). Results And Discussion. The analysis of the data obtained showed that in the case of the EDM of PCM, the angle of the location of the flushing nozzles should be taken into account in order to increase the productivity of processing deep, blind holes. It is established that the highest performance value is achieved when the nozzles are located at an angle of 15˚. The laminar motion prevails. With this arrangement of the nozzles, the value of the liquid pressure and the removal of the sludge are stable both with the EDM of PCM to a depth of 2 mm, and when processing to a depth of 15 mm. It is noted that for processing holes with a depth of 10 mm or more, it is worth considering the angle of inclination of the flushing nozzle for effective processing, it is necessary to remove eroded particles from the gap. In the process of conducting an experimental study, when processing holes with a depth of 15 mm, sticking of sludge to the electrode-tool was observed, as well as the closure of the EDM process, the occurrence of secondary discharges in the processing zone, which caused the processing to stop.
介绍聚合物复合材料(PCM)用于提高产品的机械性能和延长产品的使用寿命。对于PCM制成的产品的加工,使用电物理加工方法是标准的。其中一种方法是复制穿孔放电加工(EDM)。使用这种方法来处理PCM是由于其高物理和机械特性以及通过刀片方法处理的复杂性。考虑到PCM元件是一种粘合剂-环氧树脂,在电火花加工过程中,该树脂在孔和槽的边缘被破坏,PCM可能被认为难以加工。在PCM产品孔的电火花加工过程中,温度升高,加工区经常出现低效冷却。本文致力于在Ansys软件包中进行理论模拟,这使得基于有限元分析软件系统中的数值模拟来评估冲洗方法对PCM产品电火花加工效率的影响成为可能。这项工作的目的是提高PCM产品电火花加工工艺的生产率。方法。在仿穿孔放电智能数控机床上,采用经典实验方法进行了实验研究。工件在恒定电压U=50 V、脉冲接通时间Ton=100µs和电流I=10 a下进行处理。为了对流动进行理论模拟,使用了ANSYS CFX 20.1软件。在三个加工深度(2 mm、10 mm、15 mm)以及三个喷嘴倾角(15°、45°、75°)下进行了流量分布模拟。结果和讨论。对获得的数据的分析表明,在PCM的EDM的情况下,为了提高加工深盲孔的生产率,应该考虑冲洗喷嘴的位置角度。已经确定,当喷嘴位于15˚的角度时,可获得最高性能值。层流运动占主导地位。通过喷嘴的这种布置,无论是在PCM的EDM深度为2mm时,还是在加工深度为15mm时,液体压力的值和污泥的去除都是稳定的。值得注意的是,对于加工深度为10mm或以上的孔,为了进行有效的加工,值得考虑冲洗喷嘴的倾斜角度,有必要从间隙中去除被侵蚀的颗粒。在进行实验研究的过程中,当加工深度为15mm的孔时,观察到污泥粘附在电极工具上,以及EDM工艺的关闭,在加工区发生二次放电,导致加工停止。
{"title":"Theoretical simulation of the process interelectrode space flushing during copy-piercing EDM of products made of polymer composite materials","authors":"E. Shlykov, Timir Ablyaz, K. Muratov","doi":"10.17212/1994-6309-2022-24.2-25-38","DOIUrl":"https://doi.org/10.17212/1994-6309-2022-24.2-25-38","url":null,"abstract":"Introduction. Polymer composite materials (PCM) are used to improve the mechanical properties and increase the working period of products. For the processing of products made of PCM, the use of electrophysical processing methods is standard. One of these methods is copy-piercing electrical discharge machining (EDM). The use of such methods for processing PCM is due to its high physical and mechanical characteristics and the complexity of processing by blade methods. Considering the fact that the PCM element is a binder – epoxy resin, which is destroyed at the edges of the resulting holes and grooves during EDM, PCM can be considered difficult to process. During the EDM of holes in PCM products, the temperature rises, and inefficient cooling often occurs in the processing zone. The paper is devoted to theoretical simulation in the Ansys package, which makes it possible to evaluate the impact of flushing method on the efficiency of the EDM of PCM products based on numerical simulation in finite element analysis software systems. The aim of the work is to increase the productivity of the processes of EDM for PCM products. Methods. Experimental studies were carried out according to the method of a classical experiment on a copy-piercing electrical discharge Smart CNC machine. The workpiece was processed at a constant voltage U = 50 V, pulse on-time Ton = 100 µs and current: I = 10 A. For theoretical simulation of the flow, the ANSYS CFX 20.1 software was used. Flow distribution simulation was carried out at three processing depths (2 mm, 10 mm, 15 mm), as well as at three nozzle inclination angles (15°, 45°, 75°). Results And Discussion. The analysis of the data obtained showed that in the case of the EDM of PCM, the angle of the location of the flushing nozzles should be taken into account in order to increase the productivity of processing deep, blind holes. It is established that the highest performance value is achieved when the nozzles are located at an angle of 15˚. The laminar motion prevails. With this arrangement of the nozzles, the value of the liquid pressure and the removal of the sludge are stable both with the EDM of PCM to a depth of 2 mm, and when processing to a depth of 15 mm. It is noted that for processing holes with a depth of 10 mm or more, it is worth considering the angle of inclination of the flushing nozzle for effective processing, it is necessary to remove eroded particles from the gap. In the process of conducting an experimental study, when processing holes with a depth of 15 mm, sticking of sludge to the electrode-tool was observed, as well as the closure of the EDM process, the occurrence of secondary discharges in the processing zone, which caused the processing to stop.","PeriodicalId":42889,"journal":{"name":"Obrabotka Metallov-Metal Working and Material Science","volume":" ","pages":""},"PeriodicalIF":0.4,"publicationDate":"2022-06-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49046950","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Machining technology, digital modelling and shape control device for large parts 大型零件的加工技术、数字建模和形状控制装置
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2022-06-15 DOI: 10.17212/1994-6309-2022-24.2-6-24
S. Timofeev, A. Grinek, A. Hurtasenko, I. Boychuk
Introduction. The development of a method for controlling the accuracy parameters of large axisymmetric bodies is an urgent task that is being solved by specialists from various industries. Application for adjustment and correction of machining based on the measurement of surface shape parameters directly during machining is shown. Purpose of work is to improve mobile processing technologies using special measuring devices and processing module. For this, the problems of development and analysis of mathematical models that describe the process of basing and machining of a riding ring as a cylindrical object with a non-stationary axis of rotation is solved. A study of the methodology is carried out, control schemes are designed, and equipment for processing mobile devices is developed. The methods of research are the analysis of the developed mathematical models, taking into account the assignment of effective technological modes. Three-dimensional and simulation modeling of processing, hardware-software implementation of proposed solutions, and statistical processing of measurement results are carried out. Results and discussion. The algorithm and methodology are tested with a three-dimensional simulation model. The presented methodology for measuring and calculating the allowance for mechanical restoration can significantly reduce machining time compared to active form control and compared to the traditional method of assigning an allowance for machining. The measurement and adjustment of the allowance based on the measurement data is not carried out after each measurement, but only in the case of transition to finishing transitions or for accuracy control. It is determined that by providing a single technological base for each individual technological transition within the framework of the mobile technology of machining of the rolling surface of the riding rings of technological drums, the accuracy and speed of processing increase. An original design of the device for monitoring parameters is developed; an experimental assembly and a laboratory model of the riding ring are made.
介绍开发一种控制大型轴对称体精度参数的方法是各行业专家正在解决的一项紧迫任务。显示了在加工过程中直接测量表面形状参数来调整和校正加工的应用。工作的目的是利用特殊的测量设备和处理模块改进移动处理技术。为此,解决了将骑环描述为具有非平稳旋转轴的圆柱形物体的基础和加工过程的数学模型的开发和分析问题。对该方法进行了研究,设计了控制方案,并开发了处理移动设备的设备。研究方法是对所开发的数学模型进行分析,同时考虑到有效技术模式的分配。对处理过程进行了三维和仿真建模,提出了解决方案的软硬件实现,并对测量结果进行了统计处理。结果和讨论。该算法和方法用三维仿真模型进行了测试。与主动形状控制相比,以及与分配加工余量的传统方法相比,所提出的测量和计算机械修复余量的方法可以显著减少加工时间。基于测量数据的余量的测量和调整不是在每次测量之后进行的,而是仅在过渡到最终过渡的情况下或为了精度控制而进行的。可以确定的是,通过在工艺鼓的骑环滚动表面加工的移动技术框架内为每个单独的技术过渡提供单一的技术基础,可以提高加工的精度和速度。开发了用于监测参数的装置的原始设计;制作了骑环的实验组件和实验室模型。
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引用次数: 3
Features of the superposition of ultrasonic vibrations in the welding process 焊接过程中超声波振动叠加的特点
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2022-06-15 DOI: 10.17212/1994-6309-2022-24.2-50-66
S. Sundukov
Introduction. The main problem in obtaining welded joints is the nonuniform heating of the joint zone, which leads to differences in the structure and properties of the weld metal and the base metal. One of the ways to intensify the welding process is the use of ultrasonic vibrations. As a result of the analysis of methods for introducing ultrasonic vibrations into the melting zone, a method of superimposing vibrations on the elements to be welded was chosen for experimental studies. This method makes it possible to influence the welded elements throughout the entire welding cycle from the melt bath to complete crystallization of the metal. Methods. Experimental studies were carried out on plates made of carbon structural steel St3 (ASTM A568M, AISI 1017, DIN 17100) and aluminum deformable non-hardened alloy AMg4 (EN AW-5086, AW-AL Mg4, 5086). As a source of oscillations, a rod magnetostrictive oscillatory system was used, the end of which was rigidly fixed on one of the welded plates. To determine the places of application of the oscillation source and the welding zone, a calculation method is proposed based on the equality of the resonant frequencies of the used oscillatory system and the natural frequency of bending vibrations of the welding component. It is shown that the optimal places for the application of vibrations and welding will be the antinodes of oscillations, which have the maximum amplitude. Welds were obtained by the method of semi-automatic gas metal arc welding. Results and Discussion. Microstructural study of obtained samples showed a significant decrease in the proportion of dendritic segregation. The changes in the structure are the result of the effects that occur in the liquid melt when ultrasonic vibrations are introduced. The main effects are sound pressure, cavitation and acoustical streaming. The structure change mechanism consists in the dispersion of growing dendrites and crystallization nuclei under the action of shock waves and cumulative jets that occur when cavitation bubbles collapse. The formed fragments of dendrites are new crystallization nuclei that propagate through the melt pool under the action of acoustic currents. Then the process is repeated. The resulting effects affect the kinetics of the crystallization process – the degree of supercooling increases, the number of crystallization nuclei formed per unit time increases, and the rate of its growth decreases. Changes in the structure of the weld metal lead to an increase in the quality of the welded joint, which reduces welding deformations, increases the tensile strength and significantly increases ductility.
介绍。焊接接头的主要问题是接头区加热不均匀,导致焊缝金属和母材的组织和性能存在差异。强化焊接过程的方法之一是使用超声波振动。通过对将超声振动引入熔区方法的分析,选择了在待焊构件上叠加振动的方法进行实验研究。这种方法可以在从熔浴到金属完全结晶的整个焊接周期中影响被焊接元件。方法。在碳素结构钢St3 (ASTM A568M, AISI 1017, DIN 17100)和铝可变形非硬化合金AMg4 (EN AW-5086, AW-AL Mg4, 5086)板上进行了实验研究。作为振荡源,采用棒磁致伸缩振荡系统,其末端刚性固定在其中一块焊接板上。为了确定振荡源的应用位置和焊接区域,提出了一种基于所用振荡系统的谐振频率与焊接构件弯曲振动固有频率相等的计算方法。结果表明,振动和焊接的最佳应用位置是振幅最大的振荡正极。采用半自动气体保护金属电弧焊进行焊接。结果和讨论。所得样品的显微组织研究表明,枝晶偏析的比例显著降低。结构的变化是在引入超声波振动时发生在液体熔体中的效应的结果。主要的影响是声压、空化和声流。其结构变化机制是在空化气泡崩塌时产生的激波和累积射流作用下生长的枝晶和结晶核的弥散。形成的枝晶碎片是在声电流作用下在熔池中传播的新的结晶核。然后重复这个过程。由此产生的影响影响结晶过程的动力学——过冷程度增加,单位时间内形成的结晶核数量增加,其生长速度降低。焊缝金属结构的变化导致焊接接头质量的提高,从而减少了焊接变形,提高了抗拉强度,并显著提高了延展性。
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引用次数: 0
Influence of boriding and aluminizing processes on the structure and properties of low-carbon steels 渗硼和渗铝工艺对低碳钢组织和性能的影响
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2022-06-15 DOI: 10.17212/1994-6309-2022-24.2-91-101
P. Gulyashinov, U. Mishigdorzhiyn, N. Ulakhanov
Introduction. Boriding and aluminizing are among the effective methods for improving the performance properties (corrosion resistance, heat resistance and wear resistance) of machine parts and tools. Solid-phase methods of carrying out techniques of thermochemical treatment (TCT) require long-term exposure at elevated temperatures, which negatively affects the structure and properties of the base material. From these positions, the selection of reasonable temperature-time parameters of solid-phase boriding and aluminizing processes is an urgent task. The purpose of this work is to assess the effect of low-temperature boriding and aluminizing processes on the structure and microhardness of diffusion layers on the surface of low-carbon steels. The paper considers two grades of steels with a carbon content of up to 0.4%: low-carbon steel St3 and alloy steel 3Cr2W8V. The use of the second steel is due to the need to identify the effect of alloying elements in steel on the thickness of diffusion layers and its composition. Powder mixtures based on boron carbide and aluminum carbide are selected as sources of boron and aluminum. Results and discussions. It is found at a process temperature of 900 °C and holding for 2 hours after boriding, iron borides are formed on the surface of both steels. At the same time, two borides FeB and Fe2B are detected on St3 steel by X-ray phase analysis (XRD), and only the Fe2B phase is detected on 3Cr2W8V steel. After aluminizing, aluminum-containing phases such as Al5Fe2, Na3AlF6 and Al2O3 are formed in both steels. The thickness of the resulting diffusion layer on St3 after boriding is 35 μm, after aluminizing – 65 μm. The thickness of the diffusion layer on 3Cr2W8V steel is equal to 15 μm after boriding and 50 μm after aluminizing, which is significantly less than on carbon steel and is obviously due to the effect of alloying elements. It is established that TCT leads to a significant increase in the microhardness of the samples surface. Thus, the maximum microhardness of St3 steel increased to 2,000 HV, and the maximum microhardness of 3Cr2W8V steel increased to 1,700 HV after boriding. The microhardness after aluminizing is comparable for both steels and is equal to 1,000-1,100 HV. Elemental analysis of the upper sections of the diffusion layers shows that the content of boron (7-9%) and aluminum (50-53%) corresponds to the detected XRD iron borides and aluminides. In all cases, there is a gradual decrease in the diffusing elements in the direction from the surface to the base.
介绍渗硼和渗铝是提高机械零件和工具性能(耐腐蚀、耐热和耐磨)的有效方法之一。实施热化学处理(TCT)技术的固相方法需要在高温下长期暴露,这会对基材的结构和性能产生负面影响。从这些位置出发,选择合理的固相渗铝工艺的温度-时间参数是一项紧迫的任务。本工作的目的是评估低温硼化和渗铝工艺对低碳钢表面扩散层结构和显微硬度的影响。本文考虑了碳含量高达0.4%的两种钢:低碳钢St3和合金钢3Cr2W8V。第二种钢的使用是由于需要识别钢中合金元素对扩散层厚度及其成分的影响。选择基于碳化硼和碳化铝的粉末混合物作为硼和铝的来源。结果和讨论。研究发现,在900°C的工艺温度下,硼化后保持2小时,两种钢的表面都会形成铁硼化物。同时,通过X射线相分析(XRD)在St3钢上检测到两种硼化物FeB和Fe2B,而在3Cr2W8V钢上仅检测到Fe2B相。渗铝后,在两种钢中都形成了含铝相,如Al5Fe2、Na3AlF6和Al2O3。硼化后St3上的扩散层厚度为35μm,渗铝后为-65μm。3Cr2W8V钢渗硼后的扩散层厚度为15μm,渗铝后为50μm,明显小于碳钢,这显然是由于合金元素的影响。研究表明,TCT能显著提高试样表面的显微硬度。因此,经硼化处理后,St3钢的最大显微硬度提高到2000HV,3Cr2W8V钢的最大微硬度提高到1700HV。渗铝后的显微硬度对两种钢来说都相当,等于1000-1100 HV。扩散层上部的元素分析表明,硼(7-9%)和铝(50-53%)的含量对应于检测到的XRD铁硼化物和铝化物。在所有情况下,散射元件在从表面到基底的方向上逐渐减少。
{"title":"Influence of boriding and aluminizing processes on the structure and properties of low-carbon steels","authors":"P. Gulyashinov, U. Mishigdorzhiyn, N. Ulakhanov","doi":"10.17212/1994-6309-2022-24.2-91-101","DOIUrl":"https://doi.org/10.17212/1994-6309-2022-24.2-91-101","url":null,"abstract":"Introduction. Boriding and aluminizing are among the effective methods for improving the performance properties (corrosion resistance, heat resistance and wear resistance) of machine parts and tools. Solid-phase methods of carrying out techniques of thermochemical treatment (TCT) require long-term exposure at elevated temperatures, which negatively affects the structure and properties of the base material. From these positions, the selection of reasonable temperature-time parameters of solid-phase boriding and aluminizing processes is an urgent task. The purpose of this work is to assess the effect of low-temperature boriding and aluminizing processes on the structure and microhardness of diffusion layers on the surface of low-carbon steels. The paper considers two grades of steels with a carbon content of up to 0.4%: low-carbon steel St3 and alloy steel 3Cr2W8V. The use of the second steel is due to the need to identify the effect of alloying elements in steel on the thickness of diffusion layers and its composition. Powder mixtures based on boron carbide and aluminum carbide are selected as sources of boron and aluminum. Results and discussions. It is found at a process temperature of 900 °C and holding for 2 hours after boriding, iron borides are formed on the surface of both steels. At the same time, two borides FeB and Fe2B are detected on St3 steel by X-ray phase analysis (XRD), and only the Fe2B phase is detected on 3Cr2W8V steel. After aluminizing, aluminum-containing phases such as Al5Fe2, Na3AlF6 and Al2O3 are formed in both steels. The thickness of the resulting diffusion layer on St3 after boriding is 35 μm, after aluminizing – 65 μm. The thickness of the diffusion layer on 3Cr2W8V steel is equal to 15 μm after boriding and 50 μm after aluminizing, which is significantly less than on carbon steel and is obviously due to the effect of alloying elements. It is established that TCT leads to a significant increase in the microhardness of the samples surface. Thus, the maximum microhardness of St3 steel increased to 2,000 HV, and the maximum microhardness of 3Cr2W8V steel increased to 1,700 HV after boriding. The microhardness after aluminizing is comparable for both steels and is equal to 1,000-1,100 HV. Elemental analysis of the upper sections of the diffusion layers shows that the content of boron (7-9%) and aluminum (50-53%) corresponds to the detected XRD iron borides and aluminides. In all cases, there is a gradual decrease in the diffusing elements in the direction from the surface to the base.","PeriodicalId":42889,"journal":{"name":"Obrabotka Metallov-Metal Working and Material Science","volume":" ","pages":""},"PeriodicalIF":0.4,"publicationDate":"2022-06-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42899713","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
On the issue of limiting the irregular motion of a technological machine within specified limits 关于将工艺机器的不规则运动限制在规定范围内的问题
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2022-06-15 DOI: 10.17212/1994-6309-2022-24.2-67-77
Yuriy Podgornyj, T. Martynova, V Yu Skeeba
Introduction. The problem of regulating speed fluctuations for any mechanism is essential, because the time interval of this movement is the working time during which the main technological operation is performed. In this case, the question may arise about the regulation of motion speeds both during acceleration, idling of the machine, and during the execution of the main technological operation. The main qualitative indicator of the satisfactory operation of any machine is the motion irregularity ratio, the value of which depends on the ratio of the maximum, minimum and average speeds of the drive shaft. Particularly acute is the problem of determining the motion irregularity ratio of the machine, taking into account the characteristics of the motor. In this case, the machine is considered as a system consisting of a single mass. The elasticity of the elements included in the machine is neglected. An analysis of the scientific literature in this area indicates that insufficient attention is paid to the study of rotation irregularities and its influence on the dynamics of mechanisms, especially when it comes to solving equations taking into account the characteristics of the motor. The purpose of this work is to develop a methodology that allows determining and regulate the non-uniform rotation of the drive shaft, taking into account the characteristics of the motor, the forces of useful resistance and the inertia of the masses of the mechanism. The relevance of the study is due to the lack of a unified methodology that allows adjusting the non-uniform rotation of the drive shaft at the stage of designing mechanisms of this type. Theory and methods. It is proposed to use the Lagrange equation of the second kind to determine the equation of machine motion in differential form. Mathematical simulation is carried out using the Mathcad and KOMPAS-3D application packages. Results and discussion. A methodology is presented that makes it possible to regulate the non-uniform rotation of the shaft. The CAE of the Mathcad system are used to determine the value of the irregularity ratio and patterns of change in these indicators are identified for total operating values that are in the range of 22-46 Nm. An analysis of the results of the calculations performed indicates that the irregularity ratio of the drive shaft rotation is 0.101. It is possible to change this ratio by changing the reduced moment of inertia by installing an additional flywheel or changing the torque of the motor shaft. The obtained results of the research made it possible to develop specific recommendations for the modernization of the drive designs for machines for mixing bulk materials and to outline ways for further research in this direction.
介绍。调节任何机械的速度波动的问题都是至关重要的,因为这种运动的时间间隔是执行主要技术操作的工作时间。在这种情况下,可能会出现在加速、机器空转和执行主要工艺操作期间运动速度调节的问题。任何机器运行是否满意的主要定性指标是运动不规则比,其值取决于传动轴的最大、最小和平均速度之比。特别急迫的是在考虑到电机特性的情况下确定机器的运动不均匀率的问题。在这种情况下,机器被认为是一个由单一质量组成的系统。机器中包含的元件的弹性被忽略了。对该领域科学文献的分析表明,对旋转不规则性及其对机构动力学的影响的研究不够重视,特别是在求解考虑电机特性的方程时。这项工作的目的是开发一种方法,允许确定和调节传动轴的非均匀旋转,同时考虑到电机的特性,有用阻力的力量和机构质量的惯性。该研究的相关性是由于缺乏一种统一的方法,允许在设计这种类型的机构阶段调整传动轴的不均匀旋转。理论与方法。提出用第二类拉格朗日方程确定微分形式的机械运动方程。利用Mathcad和KOMPAS-3D软件包进行数学仿真。结果和讨论。提出了一种方法,可以调节轴的不均匀旋转。使用Mathcad系统的CAE来确定不规则比的值,并在22-46 Nm范围内确定这些指标的变化模式。对计算结果的分析表明,传动轴的旋转不均匀率为0.101。可以通过安装额外的飞轮或改变电机轴的扭矩来改变减小的转动惯量来改变这个比率。所获得的研究结果使得有可能对混合散装材料的机器的驱动设计的现代化提出具体建议,并概述了在这个方向上进一步研究的方法。
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引用次数: 0
Calculation of temperatures during finishing milling of a nickel based alloys 镍基合金精加工时温度的计算
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2022-03-15 DOI: 10.17212/1994-6309-2022-24.1-23-32
D. Gubin, A. Kisel’
Introduction. One of the most important tasks in cutting metals and alloys is the control of the temperature factor, since temperature is one of the limitations in determining cutting conditions. This approach makes it possible to determine rational (in some cases, optimal) milling modes. Experimental methods for determining the temperature are labor-consuming, costly and not always available. The labor-consuming nature lies in the need for constant adjustment of experimental equipment due to changing cutting conditions, electrical insulation of the tool and workpiece, the appearance of parasitic electrical micro-voltage (if we are talking about temperature measurement methods with thermocouples), constant calibration of instruments and selection of thermal radiation coefficients (if we are talking about non-contact measurement methods). In this regard, there is a need for a theoretical determination of temperatures during milling with minimal use of experimental data. The purpose of the work: to develop a method for theoretical calculation of temperature during milling (cutting) of nickel-based heat-resistant materials on the example of 56% Ni -Cr-W Mo-Co-Al alloy (56% Ni, 0.1% C, 10% Cr, 6.5% W, 6% Al, 6.5% Mo, 0.6% Si, 13 % Co, 1% Fe). Research methodology. To determine theoretically the cutting temperatures, a mathematical model is formed that takes into account the mechanical and thermophysical properties of the material being processed and its change depending on the temperature variations during milling, the geometry of the cutting tool and the features of the schematization of the milling process. The experimental part of the study is carried out on a console milling machine KFPE-250 with a CNC system Mayak-610. The 56% Ni -Cr-W Mo-Co-Al material is processed with a Seco JS513050D2C.0Z3-NXT cutter with different speeds and feeds. The temperature is measured using a Fluke Ti400 thermal imager. Results and discussion. A theoretical model for calculating the temperature (for the group of 77% Ni - Cr - Ti - Al - B, 66% Ni - Cr - Mo - W - Ti - Al, 73% Ni-Cr-Mo-Nb-Ti-Al and 56% Ni -Cr-W Mo-Co-Al alloys) during milling of heat-resistant nickel-based alloys is developed, which makes it possible to predict the temperature value at the face and flank of the tool when changing cutting conditions (speed, feed, depth, cutting tool geometry), as well as the cutting temperature. An analysis of the experimental and theoretically predicted values of the cutting temperature showed a satisfactory agreement between the corresponding values.
介绍切削金属和合金时最重要的任务之一是控制温度因素,因为温度是确定切削条件的限制因素之一。这种方法可以确定合理的(在某些情况下,最佳的)铣削模式。用于确定温度的实验方法是耗费人力的、昂贵的并且并不总是可用的。劳动力消耗的本质在于,由于切削条件的变化、工具和工件的电绝缘、寄生微电压的出现(如果我们谈论的是使用热电偶的温度测量方法),需要不断调整实验设备,仪器的恒定校准和热辐射系数的选择(如果我们谈论的是非接触测量方法)。在这方面,需要在最少使用实验数据的情况下从理论上确定铣削过程中的温度。本工作的目的是:以56%Ni-Cr-W-Mo-Co-Al合金(56%Ni,0.1%C,10%Cr,6.5%W,6%Al,6.5%Mo,0.6%Si,13%Co,1%Fe)为例,建立镍基耐热材料铣削(切削)过程中温度的理论计算方法。研究方法。为了从理论上确定切削温度,形成了一个数学模型,该模型考虑了被加工材料的机械和热物理特性及其随铣削过程中温度变化的变化、切削工具的几何形状和铣削过程的示意图特征。本研究的实验部分是在KFPE-250控制台铣床上进行的,数控系统为Mayak-610。采用Seco JS513050D2C.0Z3-NXT刀具,以不同的速度和进给量对56%Ni-Cr-W-Mo-Co-Al材料进行加工。使用Fluke Ti400热成像仪测量温度。结果和讨论。建立了计算耐热镍基合金铣削过程中温度(77%Ni-Cr-Ti-Al-B、66%Ni-Cr-Mo-W-Ti-Al、73%Ni-Cr-Mo-Nb-Ti-Al和56%Ni-Cr-W-Mo-Co-Al合金组)的理论模型,这使得在改变切削条件(速度、进给、深度、切削刀具几何形状)时能够预测刀具表面和侧面的温度值以及切削温度。对切削温度的实验值和理论预测值的分析表明,相应值之间的一致性令人满意。
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引用次数: 0
Comparative study of cavitation erosion resistance of austenitic steels with different levels of metastability 不同亚稳态奥氏体钢抗气蚀性能的比较研究
IF 0.4 Q4 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2022-03-15 DOI: 10.17212/1994-6309-2022-24.1-61-72
Y. Korobov, H. Alwan, A. Makarov, V. Kukareko, V. Sirosh, M. Filippov, S. Estemirova
Introduction. Reliability-critical components of equipment working in contact with high-speed liquid media (for example, turbine blades of hydroelectric power stations, pump impellers, ship propellers) are subjected to one of the types of wear – cavitation erosion. The current study aims to select and scientifically substantiate the type of coating and its structural-phase state for the effective protection of parts from cavitation erosion. Research methods. The study carries out a comparative analysis of differences in the cavitation erosion resistance of characteristic austenitic steels, in the form of bulk material (316L) and coatings (E308L, 60Cr8TiAl), used for protection against cavitation Arc surfacing, i.e. MMA and MIG, is used for depositing the coatings. The tests are carried out on an original installation for evaluating the cavitation resistance of materials with applying ultrasound and the electrical potential difference. Results and Discussion. The results show that the 60Cr8TiAl has a higher resistance to cavitation erosion than that of E308L and 316L by 4 and 10 times, respectively. The structural factors that determine the resistance to cavitation erosion damage are identified to analyze the reasons for the differences in material resistance. Firstly, a strong dependence of the cavitation erosion resistance of austenitic steels on the intensity of the deformation martensitic transformation, developing under the influence of cavitation, is confirmed. This structural transformation contributes to an increase in cavitation resistance of the surface layer. In metastable austenitic steel, a deformation martensite (α′) is formed in the surface layer during the initial test period. This causes an increase in hardness, dissipation of the energy of external action, and the appearance of compressive stresses that prevent the occurrence of microcracks. Subsequently, additional hardening of the previously formed dispersed crystals of α′-martensite occurs. In 60Cr8TiAl, these effects are significantly stronger than that of E308L and 316L due to the higher level of metastability of austenite and formation of carbon deformation martensite.
介绍。与高速液体介质接触的设备的可靠性关键部件(例如,水电站的涡轮叶片,泵叶轮,船舶螺旋桨)遭受一种磨损-空化侵蚀。本研究的目的是选择和科学地证实涂层的类型及其结构相状态,以有效地保护零件免受空化侵蚀。研究方法。本研究对比分析了特征奥氏体钢的抗空泡侵蚀性能差异,采用本体材料(316L)和用于防空泡的涂层(E308L、60Cr8TiAl)进行电弧堆焊,即采用MMA和MIG沉积涂层。在原装置上进行了超声和电位差对材料空化阻力的评价试验。结果和讨论。结果表明:60Cr8TiAl的抗空化侵蚀性能分别比E308L和316L高4倍和10倍;确定了决定材料抗空化侵蚀损伤的结构因素,分析了材料抗蚀性差异的原因。首先,证实了奥氏体钢的抗空化侵蚀能力与在空化作用下形成的变形马氏体相变强度有很大的相关性。这种结构转变有助于增加表面层的空化阻力。在亚稳奥氏体钢中,在试验初期在表层形成形变马氏体(α′)。这导致硬度的增加,外部作用能量的耗散,以及防止微裂纹发生的压应力的出现。随后,先前形成的分散的α′-马氏体晶体进一步硬化。在60Cr8TiAl中,由于奥氏体亚稳性更高,碳变形马氏体的形成,这些效应明显强于E308L和316L。
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Obrabotka Metallov-Metal Working and Material Science
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