RATIONAL FOR REHEATING IN THE AUTOMATED LINE FOR RING BLANKS PRODUCTION

Features and requirements to the use of reheating of ring blanks in the conditions of production on the automated line are considered. An assessment is given for a technological temperature state of ring blanks at various stages of production under conditions of the automated line. For assessment of rational for reheating at production of ring blanks, a classification of ring manufacturing technology is proposed with the production of a pressed non-core blank in an open die, with the production of a pressed profile blank in a closed die, with the production of a pressed profile blank in a stamp with reverse extrusion. The technology of ring rolling with the production of a pressed non-core blank in an open die is the most economical and does not require the use of reheating in the manufacture of rings made of medium-alloy steels. The technology of ring rolling of a profile blank obtained in a closed die does not require the use of additional heating after pressing, in the case of manufacturing rings with a simplified profile on the outer or inner diameters of the ring. In the manufacture of rings with a more complex profile on the outer and inner diameters of the ring, as well as rings made of high-alloy steels, the final decision on the need for additional heating is made depending on the temperature of the end of intensive plastic deformation for the selected steel grade of the ring. The technology of ring rolling with the production of a pressed profile blank in a die with reverse extrusion requires the use of reheating after the pressing operation before the ring rolling operation, and is recommended for the manufacture of rings from medium- and high-alloy steels with a complex profile section on the outer and inner diameters, wall thicknesses, with a ratio of wall thickness to outer diameter D within h / D = 0.011...0.016 and with a ratio of wall thickness to ring height L within h / L = 0.020...0.041. The proposed recommendations are intended for use in the development of technological support for the operation of the automated ring-rolling complex at OJSC “BELAZ”.

Identification of the features of structural-phase transformations in the processing of waste from the production of high-alloy steels

This paper reports a study into the peculiarities of the structural-phase composition of the alloy obtained by using anthropogenic waste from the production of high-alloy steels involving reduction melting. That is necessary for determining the technological parameters that could help decrease the loss of alloying elements in the process of obtaining and using a doped alloy. This study has shown that at an O:C ratio in the charge of 1.84, the alloy consisted mainly of the solid solution of carbon and alloying elements in α-Fe. The manifestation of Fe3C C carbide with alloying elements as substitution atoms was of relatively weak intensity. At the O:C ratios in the charge of 1.42 and 1.17, there was an increase in the intensity of the Fe3C carbide manifestation. At the same time, the emergence of the carbide compounds W2C·Mo2C and WC was identified. Several phases with different content of alloying elements were present in the microstructure images. Cr content in the examined areas changed in the range of 0.64–33.86 % by weight; W content reached 41.58 % by weight; Mo –19.53 % by weight; V – 18.55 % by weight; Co – 3.95 % by weight. The carbon content was in the range of 0.28–2.43 % by weight. Analysis of the study results reveals that the most favorable ratio of O:C in the charge was 1.42. At the same time, the phase composition was dominated by a solid solution of the alloying elements and carbon in α-Fe. The share of the residual carbon concentrated in the carbide component was in the range of 0.52–2.11 % by weight, thereby ensuring the required reduction capability of the alloy when used. The study reported here has made it possible to identify new technological aspects of obtaining an alloy by utilizing anthropogenic waste, and whose indicators provide for the possibility of replacing part of standard ferroalloys when smelting steels without strict restrictions on carbon content.

FEATURES OF CONTACT INTERACTION IN CUTTING HIGH-ALLOY STEELS WITH CARBIDE TOOLS

It is considered the contact interaction when turning high-alloyed steels of different groups. It is revealed differences in the patterns of the contact interaction for high-alloy steels in comparison with the pearlitic steels. It is possibility that the identified differences are associated with different character of the dependence of thermal conductivity on temperature for these groups of machining steels.

A mathematical model of the double-pipe system with TBCs application

Following Rankine’s cycle efficiency, steam with ever-higher parameters is used to improve the efficiency of advanced ultra-supercritical power plants. The high steam parameters require the use of expensive high-alloy steels. Therefore, design concepts with reduced investment costs are more and more popular. In the power industry, the use of thermal barrier coatings to protect components exposed to high temperatures is becoming ever more common. The innovative concept is a double-pipe system with a thermal barrier that provides insulation for the primary pipe, in which ultra-supercritical steam flows. On the outside, the pipe is cooled by lower performance steam. The following paper presents a two-dimensional mathematical model of the proposed solution. A set of heat transfer equations allows the determination of the temperature field in the steady and transient-state operation of such a system. The numerical model is compared with the CFD one. The temperature gradient in the inner pipe wall with and without coating was determined. In addition, the response of the wall temperature to the step-change of the steam temperature was investigated. The paper shows that the use of TBCs allows reducing high-alloy steels and improving the handling properties of thick-walled components.

Reducing adhesive wear in dry deep drawing of high-alloy steels by using MMC tool

Sheet metal forming normally requires the application of lubricants to protect the tool and the sheet against wear. In the case of nonlubricated sheet metal forming, cleaning processes would not be necessary anymore and the process chain could be optimized regarding ecological and economical aspects. However, forming without lubrication leads to an intensive contact between the tool and the sheet. Thus, higher wear occurs and process reliability cannot be ensured for industrial mass production. For dry metal forming of high-alloy steels, a new tool concept must be developed to withstand the higher loads. In this work, a laser-generated tool surface with a supporting plateau of hard particles is presented. Spherical fused tungsten carbides were injected into the surface by laser melt injection. The metallic matrix of the composite was rejected by applying laser ablation. In consequence, the hard particles stood out of the matrix and were in direct contact with the sheet material. Dry and lubricated forming experiments were carried out by strip drawing with bending and deep drawing of cups. Within this work, the feasibility of dry metal forming of high-alloy steel could be demonstrated by applying the MMC surface whereby adhesive wear could be reduced.