MODERN METHODS OF SURFACING THE TOOLS
OF AGRICULTURAL TILLERS AND HARVESTERS
(Review)
V . S . S E N C H I S H I N a n d C h . V . P U L K A
T e rn o p o l I. P u lu j N ational Technical U n iv e rs ity , T e rn o p o l, U k r a in e
It is sh o w n t h a t a p p li c a ti o n o f in d u c tio n su rfacin g is t h e most pro m ising for flat p a rt s of a g ricu ltu ral m achinery w ith w all ( B M ) th ic k n e ss of 2 . 0 - 6 . 0 mm and dep o sited metal ( D M ) th ick n ess of 0 . 8 - 2 . 0 mm. In this case, m in im u m m ix in g of BM a nd D M , m inim um e q u ip m e n t cost, p o ssib ility of m echaniz ation and au to m a ti o n are pro v id ed .
K e y w o r d s : s u r fa c in g processes, e le c tric c o n ta c t s tre n g th e n in g , a g r ic u ltu r a l m a c h in e ry tools, th in p a rts, in d u c tio n su r fa c in g , a u to m a tio n
Thin flat parts are widely applied in agriculture as tools of tilling and harvesting machinery, namely: plough shares, c u ltivator hoes, skim plough discs, shredder knives, etc. which operate under the conditions of abrasive wear and consid erable static and dynamic loads. These parts should
10 V S. S E N C H I S H I N a n d C h . V . P U L K A , 2 0 1 2
have high strength and wear resistance 11 —4 1. However, during operation the metal continu ously contacts the soil and plants that, in its turn, leads to blade blunting. To ensure the cut ting properties, the tools should sharpen th em selves during operation. Bimetal (two-layer) working parts are th e most suitable for these conditions. Their strength is ensured by base ma terial from which the lool is made, and wear resistance and self-sharpening are provided by
Figure 1. S chem atic of disc c u t t e r design [ 12 J: a — nondriven; b — driven
the cladding layer deposited on the base metal. Self- sharpening depends on the ratio of thickness and wear resistance of base and cladding layers [5]:
E2^2 0) = -- —,
&\h\
sequent heating up to th e tem p e ra tu re , at which their sintering and form ation of a strong diffusion bond w ith th e p a rt take place. This technology is applied a t s tre n g th e n in g of tille r disc cutters, which should have a w ear-resistant c u ttin g edge and should sharpen them selves in operation.
F igure 1 shows disc knives, surfaced by pow der-like hard alloy by electric c o ntact m ethod, and Figure 2 shows a machine for strip w elding to skim plough disc f l , 12].
In [13] a technological process of elcctric con t a c t surfacing of a share by flux-cored wire of segmented cross-section is proposed. In this case, th e process of flux-cored wire surfacing runs in tw o stages: cold com pacting of th e powder core and, as a consequence, d eform ation of filler m a terials in th e zone of c o n ta c t w ith th e part; s u r facing process proper, which provides h eating of flux-cored wire at th e segm ent to p, in the zone of intensive heat evolu tion , deform ation p ropa gation to peripheral zones, m elting and w elding of th e shell to the base w ith sim ultaneous sinter ing of th e pow der core. Figure 3 shows a share surfaced by th e above technology.
A dvantages of this process are absence of base metal p e n e tratio n , minimum deform ations of sur faced parts, ab ility to deposit th in layers, high he a tin g rate, which may reach several thousand degrees per second. A d isadv antag e is a low ef ficiency of the process, absence of batch-produc- tion of the e q uipm e n t, and non-uniform quality of th e deposited m etal, as well as com plexity of m an ufactu ring flux-cored wire of segment sec tion.
where e , , e2 is th e resistance of base and c ladding layers, respectively; h v h 2 is th e thickness of the base and clad din g layers, respectively.
The best self-sharpening is provided a t co = 1.5. Various surfacing processes are applied for tool strengthening, namely: electric contact, plasma, electric arc, explosion cladding, induction and other strengthening techniques [4, 6-11 ].
Known is a m ethod of surfacing ag ricultural machinery tools, using electric c o n ta c t s tr e n g th ening [4, 6 12, 13]. W it h this m eth o d th e filler material can be powders, wires and strips. The principle of th e tec hnology is ap p licatio n on the p a rt surface of a po w der-like w ear-resistant hard material (c h a rg e ), strip and wire w ith th eir sub
Figure 2. Genera l view of m ach in e for s t r ip w e ld in g t o skim plough disc based on u p -g r a d e d M S I i P R - 3 0 0 / 1 2 0 0 ma
To obtain bimetal tools, namely skim plough discs, it is proposed to ap p ly th e process of elec tric c on tact cladding by a w ear-resistant strip [14]. To ensure the specified stre n g th and elas ticity disc knives are su b je c ted to b u lk q uenching and tem p erin g before cladding. Scale formed d u r ing rolling and he a t tre a tm e n t, is removed by etching in 20 % s ulph u ric acid so lution w ith a d dition of 1 % in h ib ito r O P -1 , h eated up to the tem p e ra tu re of 70 °C. After e tching, w ashing and drying, the disc is considered to be fit for strip cladding. The m ain d isad v antages of this m ethod are high labour c o nsum ption of p re p a ra to ry op erations, c om plexity of strip m an u fa ctu rin g from highly w ear-resistant alloys, and low stre n g th of welded layers.
M ethods of cla d d in g by explosion and rolling arc used to s tre n g th e n th e w o rking surfaces of various flat p arts, in clu d in g tille r tools [15]. Ad vantages of explosion c la d d in g include the high speed of the process, a b ility of jo in ing metals, which c annot be p roduced or are d ifficult to p ro duce by o th er m ethods, and relativ e sim plicity of the technology (absence of th e need for ap p li cation of complex e q u ip m e n t) [15]. In Czechia explosion clad din g tec hnology was used in p ro duction of bim etal knives an d o th er flat parts. Com pared to tra d itio n a l m etallurgical process of casting cladding, explosion surfacing a p plication is technically and econom ically s u b s ta n tia te d
P W I developed and tried out a m eth od of producing a w ear-resistan t bimetal at rolling of packets with po w de r PG-C1 [16], which is based on the principle of auto -v acu u m pressure w eld ing. In [17], this process was applied to produce tool bimetal w ith a cla d d in g layer of P R 10R6M5 powder. The m ain d isa d v a n tag e of th e process is making a large-sized packet, related to th e need for pow der com paction to create a m inim um vol ume of air in the p acket c avity t h a t is elim inated using pow der pre-pressing. In [18] it is shown th a t at m anu fa ctu re of bim etal sections for tiller tools c ladding layer p ow d e r PG-S1 was first com pacted by the m ethod of hot isostatic pressing. However, indu strial app licatio n of this te c h n o l ogy is p revented by com p lexity and high labour consumption.
W ork s [7, 8, 1 9-21] describe th e technology of plasma surfacing, which is applied in m a n u facturing of m u ltib la d e m e ta l-c u ttin g tools (end mills, e tc .), as well as c u ttin g edges of disc and flat cu tters of various purpose. Pow ders of high speed steels, as well as v an a d iu m -c o n tain in g al loys, are used as surfacing m aterials. This sur facing process allows com p aratively easily
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trolling the energy, heat and gas-dynamic p a rameters of a plasma j e t in wide ranges, th a t eventu ally allows o b tain in g a deposited layer w ith specified physico-chemical and mechanical properties.
Technology of p lasm a-pow der surfacing of pa per c u ttin g machine knives was developed. Re sistance of batch-p rodu ced knives w ith o u t sur facing is determ ined by th eir wearing time, de p e n d e n t on s tre n g th , hardness, mechanical prop erties and some other characteristics of steel [7, 8, 20]. B lank for surfacing has a groove, which allows p ractically e lim ina tin g deform ation after surfacing and edge effect arising at edge surfac ing. P a p e r-c u ttin g knives were surfaced by plasm a-pow der m ethod for several steel types and alloys. After surfacing th e blank is subjected to two-tim es a n nealing a t the tem pe ra ture of 5 4 0 - 560 °C, c u ttin g , stra ig h te n in g and machining.
The a dvantages of plasm a-pow der surfacing are slight penetratio n of base m e t a l , high qu ality of deposited layer, and possibility of deposition of th in layers (1~5 m m ), using a wide range of filler m aterials. The disadvantages include rela tively low efficiency and need for complex and expensive equ ip m ent, as well as high require m ents to size d istrib u tio n and shape of powder granules t h a t makes its cost much higher, and this limits the application of this process.
To improve the perform ance of tiller tools (sh re d d e r knives, c u ltiv a to r hoes, plough shares and o th er p a rts ) P W I proposed spot stre n g th e n ing using arc surfacing with PP-AN170 flux- cored wire [22]. H e ig h t of stre n g th e n in g spot is equal to 1 -3 mm, and base metal penetration dep th is 2 - 4 mm. Surfacing is performed a t re verse polarity . P e n e tra tio n dep th at spot s tre n g th e n in g is reg ula te d by changing the cur rent, voltage and arcing time. Figure 4 shows the general view of a ploug h share surfaced by flux-cored wire, before and after service. A dis a d v a n ta g e of this process is high labo u r and m a terial costs for m a n u fa ctu rin g the parts.
In [10, 2 3 -2 5 ] the technology of s tre n g th e n ing th e w o rk ing surfaces of c u ltiv a to r hoes by local s tre n g th e n in g is proposed. The essence of this m ethod consists in th a t beads are deposited on the hoe o u ter surface by arc surfacing with 40 mm step a t 25° angle to the hoe blade. Figure 5 shows the general view of the stren g thened hoc. A disadvantage of this m ethod arc high labour costs and non -u nifo rm ity of bead deposition, which depends on w e ld e r ’s qualifications.
Also k n ow n is the technology of im provem ent of tille r tool w ear resistance by carbonization of
Figure 6. G en eral view of share st r e n g th e n e d by m etal- ce ramic p lates [11]
F igure 4. Genera l vie w of s urfaced share before ( a ) and after ( b ) service [22]
the surface layer by carbon electrode [26]. The principle of th e m ethod consists in t h a t at carbon clectrode c o n ta c t w ith th e p a rt, carbon from the electrode goes into th e base metal as a result of a spark discharge, form ing on its surface a ce- m entite layer, th e hardness of which is much higher th an t h a t of base metal. This m ethod was not widely accepted, because of th e com plexity of the technological process.
W o rk s [11, 27] propose th e technology of re conditioning and s tr e n g th e n in g of plough shares by brazing on m etal-ceram ic plates. The essence of this m etho d consists in t h a t h a rd alloy plates in a continuous and in te r m i tt e n t a rra n g e m e n t are brazed-on from th e facc side of th e share blade. To realize th e process, a slot of 1 .5 -2 .0 mm depth is milled out, th e n L63 braze alloy is placed into it, on which T 15K 6 and V K 8 metal-ceramic plates are placed la te r on. Braze alloy heating is performed by the flame process, after brazing-on th e share is placed into a th erm o -in s u la tin g tan k , heated up to the te m p e ra tu re of 620 °C, to gethe r with which it cools down to room tem p e ra tu re (F ig u re 6).
The main a d v a n ta g e of tool stre n g th e n in g by metal-ceramic plates is low ering of d r a u g h t re sistance, which allows th e m achine working speed to be increased, th u s increasing p loughing efficiency.
A disad van tage of this process are high cost and labour consum ption related to the tec h n o l ogy of p a rt m anu facturin g .
O th e r m ethods of tille r tool s tren gth enin g were also developed. They include surfacing us ing electronic am plifier [28], laser surfacing [ 2 9 - 31], etc. H ow ever, because of the com plexity of t h e tec hnology and lack of e q uipm ent, its imper fection and high cost, these processes have not found any industrial app licatio n so far.
In d uctio n surfacing m ethod is widely used for stre n g th e n in g th in fla t parts, including agricul tu ra l m achinery tools. In [3 2 -3 4 ] a technology of sim ultaneous in duction surfacing of thin shaped discs over th e e n tire w o rk ing surface is proposed. Surfacing is performed using a special charge, consisting of a m ixtu re of wear-resistant pow der-like hard alloy and flux. Charge is a p plied on th e p a rt surface in th e form of a layer of th e required thickness (F ig u re 7). After th a t th e p a rt is placed inside th e in du ctor (F ig u re 8), in which th e pow er source is a high-frequency generator. At passage of high-frequency c urrents through th e inductor, eddy c urrents are induced in the surface layers of th e p a rt to be surfaced, which heat th e part, and the charge melts from its surface [32]. A dvantages of th e m ethod in clude ability of thin layer deposition, high effi ciency, ability of m echanization and autom ation of th e process. The d isadvantages arc a high e n ergy consum ption, base metal overheating, and filler m aterials sho uld be low er-m elting than the base metal. Despite th e above-said, this m ethod is th e m ost widely accepted in th e enterprises m anu fa ctu rin g a g ric u ltu ra l m achinery, ploughs, skim ploughs, c u ltiv a to r hoes, etc. [32].
To improve the labour conditions and process efficiency at induction surfacing of thin flat parts, in p a rtic u la r bits and hoes of cultivators, th e autho rs developed semi-automatic machines
Figure 5. G eneral view of hoc a fte r local s t re n g t h e n i n g [10]
Figure 7. Dev ice for ch a rg e fi llin g ( a ) a n d s urfaced disc ( b ) [341
F igure 8. D ev ice for su rfacin g t h e disc in t w o - t u r n circula r in d u c to r [34]: a — to p view; b — side view
and autom atic lines [33]. For surfacing of c u lti vator knives having a cu rv ilin ear c u ttin g surface, carouscl-type units are a p plied, in which wedge- shaped shears can be surfaced. The main disad v antage of these lines an d machines is a low ef ficiency of th e surfacing process proper, as well as low level of m echanization in term s of blank loading, charge filling and unloading.
To improve th e efficiency of the process of induction surfacing of th in shaped discs — shed- der knives of beet harvesters — by continuous- successive and sim ultan eo us surfacing m ethods, pro d u ctio n lines were developed and p u t into production 1321, which allow m echanization and a u to m ation of th e process, in clu d in g loading and unloading of th e blanks, an d th e ir m ovem ent in the roto r device, placin g th em in th e positions of charge filling an d surfacing an d removal after surfacing.
Im provem ent of ind u ctio n surfacing of thin flat parts is performed in th e follow ing direc tions: im provem ent of w ear resistance of th e de posited metal layer, optim izatio n of the heating mode in o rder to save power, as well as design param eters of inductors an d hea tin g systems for surfacing discs of a rb itra ry diam eters and surfac ing zone dimensions, proceeding from technology needs, w ith o u t a llo w in g for shielding of
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magnetic fields and allo w in g only for electro m agnetic shielding, as well as combined shielding of electrom agnetic and therm al fields sim ultane ously; m athem atical sim ulation of the surfacing process to d eterm in e residual stresses, strains and displacem ents of parts; m echanization and a u to
mation of surfacing processes takin g into account ccological c o m p atib ility of the process and p ro tection of man from the im p act of electrom agnetic and therm al fields [32].
To improve wear resistance of deposited metal of tillers, in [3 5 -3 9 ] it is proposed to apply part vibration after surfacing. The essence of this m ethod consists in t h a t a large num ber of mi croshocks w ith the respective frequency and am p litu d e of 0.5 mm, which are caused by the impact of processing tool oscillations, are successively applied to th e deposited layer for 20 s. The main a d va nta ge at a p plication of this technology is d evelopm ent of a uniform and more fine-grained s tru c tu re of th e deposited layer, t h a t leads to 25 % increase of deposited metal hardness. High labour consum ption a n d cost related to applica tion of a dditional technological operations after surfacing, should be regarded as the disadvan tages of this process.
W orks [4 0 -4 2 ] describe the technology of vi bration tre a tm e n t of welded jo ints of oil and gas
47
Figure 9. S chem atic of in d u c t io n su rfacin g of th in flat parts w ith vibration a p p lic a tio n d u r i n g su rfa cin g: / — .inductor;
2 — table; 3 — v i b r a t o r (a r r o w s sh ow direction of vib ration
a p p li c a ti o n ); 4 — p a rt ; 5 — p o w d er-lik e h ard alloy
equipm ent. This tech nolog y allows lowering the level of residual stresses and strains, arising after w elding. It, however, has not y e t become w idely accepted, because of the com plex technological process and e quipm ent.
F u rth e r im prov em en t of inductio n surfacing technology is achieved using horizontal and ver tical v ibration to increase th e w ear resistance and lower th e deform ation of th in fla t parts, which consists in t h a t v ib ra tio n a t a certain frequency and am p litu d e ( F ig u re 9) is intro d u ced, when the pow der-like w ear-resistan t h a rd alloy starts m elting and it is c o n tin u ed up to its complete m elting and solidification [4 3 J. W e a r resistance and lower deform ations are achieved due to for mation of a fine-grained s tr u c tu r e and more fa vourable distrib u tio n of carbides in the deposited metal, compared to surfacing w i t h o u t vibration. The auth ors developed m ethods and devices for surfacing th in fla t parts w ith app licatio n of hori zontal and vertical v ibrations. C o n d u cted inves tigations of th e s tru c tu re , w ear resistance and hardness of th e deposited m etal showed its a d vantages compared to t h e c u rre n tly available methods of ind uction surfacing and need to de velop a m athem atical model of the process, which would allow assessment of th e influence of me chanical vibrations on th e physical essence of refinem ent of deposited m etal s tru c tu re and its service properties.
Results of im provem ent of th e process of in duction surfacing of a g ric u ltu ra l machinery tools, conducted by th e au th o rs w ith in tro d u c tion of horizontal and vertical v ib ra tio n , were published in [ 4 3 - 4 6 1.
Thus, analysis of th e m odern surfacing m eth ods showed t h a t for th in fla t p a rts of tilla ge ag ricultural m achinery, in clu din g discs, w ith base metal and deposited layer thickness of 2.0- 6.0
and 0.8- 2. 0 mm, respectively, the most widely
accepted and prom ising m etho d is induction sur facing w ith o u t base metal m ixing with the de posited metal. This m eth o d is th e m ost readily a d a p ta ble to fabrication due to a p plication of simple e quipm ent, sim plicity of the surfacing
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Theprocess proper, and no requirement, of a high qualification of surfacing operators, and possi bility of process m echanization and autom ation ( t h a t is im p o rta n t in batch p ro du ction ). It is being c o n s ta n tly improved in term s of increasing th e efficiency, wear resistance, and uniform ity of deposited metal layer thickness, pow er saving, as well as lowering p a rt deform ation.
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