Purpose: Manufacture of cutters with carbide elements used in the construction of road cutters, and mounted in special tool holders operating under conditions of intense wear and increased load when removing asphalt concrete. The developed technology is based on the process of high-speed hot extrusion (SGV) of bimetallic products with increased performance properties.
Scope of application, analogues, novelty and advantages of the development: The technology is intended for the manufacture of cutters for road construction and mining machines (cutters for opening the roadbed and soil). The main manufacturers of road cutters abroad are such companies as "WIRTGEN" (Germany), "KENNAMETAL" (USA), "Element Six" (Germany). In the CIS countries, the main manufacturers of cutters are JSC Kirovgrad Plant of Hard Alloys (RF), Amkodor cutter DZ-7 (RB). The most common cause of premature failure of the cutters is the low technological strength of the solder joint of the carbide tip. The developed resource-saving technology is based on new principles of manufacturing a bimetallic cutter. The essence of the invention lies in the fact that a cylindrical billet is made composite with a base of low-alloy steel up to (90%), and its working part is made of carbide material VK 8. Moreover, spent finger milling cutters of machining industries are used as the billet of the working part. After heating the composite billet to the stamping temperature, high-speed hot extrusion is carried out with the shaping of the cutter and the formation of a connection of dissimilar materials in one technological transition. Unlike soldered, this compound has significant strength and higher performance properties.
Economic efficiency: A positive economic effect has been established from the use of incisors obtained using a new technology.
Commercialization of the development can be carried out by transferring technology, creating a joint production, providing technical assistance during implementation, selling finished products, conducting scientific research according to Customer requirements.
Scientific and technical significance: The competitive advantages of the developed technology are the following parameters:
– in order to save energy resources, stamping by the SGV method allows you to obtain a bimetallic cutter in one technological transition with subsequent minimal machining;
– the cutters obtained using the new SGV technology allow to implement the mode of high-temperature thermomechanical processing (VTMO) in order to strengthen the steel part of the cutter with an increase in its toughness by 40-50%, technological strength by 30-40%, resistance to abrasive wear by 25-40%, which leads to an increase in its resistance by 1.5 times;
– high–speed impact in the VTMO mode on the composite workpiece allows you to produce with a fine-grained (grain score 12-14) hardened surface layer of the steel part of the cutter, saturated with fine carbides (58 – 59HRC) due to localization of deformation and a working tungsten-cobalt working part (75 - 80HRC). An essential innovative feature in the developed technological process is the formation of a welded joint of dissimilar materials, which ensures high quality and strength of the joint. For the developed technological process, deformation rates of 30 – 80 m /s and heating temperatures of 1000 – 1100°C are optimal, which allow controlling the direction of the joint flow and the processes of joining dissimilar materials.
Scope of application, analogues, novelty and advantages of the development: The technology is intended for the manufacture of cutters for road construction and mining machines (cutters for opening the roadbed and soil). The main manufacturers of road cutters abroad are such companies as "WIRTGEN" (Germany), "KENNAMETAL" (USA), "Element Six" (Germany). In the CIS countries, the main manufacturers of cutters are JSC Kirovgrad Plant of Hard Alloys (RF), Amkodor cutter DZ-7 (RB). The most common cause of premature failure of the cutters is the low technological strength of the solder joint of the carbide tip. The developed resource-saving technology is based on new principles of manufacturing a bimetallic cutter. The essence of the invention lies in the fact that a cylindrical billet is made composite with a base of low-alloy steel up to (90%), and its working part is made of carbide material VK 8. Moreover, spent finger milling cutters of machining industries are used as the billet of the working part. After heating the composite billet to the stamping temperature, high-speed hot extrusion is carried out with the shaping of the cutter and the formation of a connection of dissimilar materials in one technological transition. Unlike soldered, this compound has significant strength and higher performance properties.
Economic efficiency: A positive economic effect has been established from the use of incisors obtained using a new technology.
Commercialization of the development can be carried out by transferring technology, creating a joint production, providing technical assistance during implementation, selling finished products, conducting scientific research according to Customer requirements.
Scientific and technical significance: The competitive advantages of the developed technology are the following parameters:
– in order to save energy resources, stamping by the SGV method allows you to obtain a bimetallic cutter in one technological transition with subsequent minimal machining;
– the cutters obtained using the new SGV technology allow to implement the mode of high-temperature thermomechanical processing (VTMO) in order to strengthen the steel part of the cutter with an increase in its toughness by 40-50%, technological strength by 30-40%, resistance to abrasive wear by 25-40%, which leads to an increase in its resistance by 1.5 times;
– high–speed impact in the VTMO mode on the composite workpiece allows you to produce with a fine-grained (grain score 12-14) hardened surface layer of the steel part of the cutter, saturated with fine carbides (58 – 59HRC) due to localization of deformation and a working tungsten-cobalt working part (75 - 80HRC). An essential innovative feature in the developed technological process is the formation of a welded joint of dissimilar materials, which ensures high quality and strength of the joint. For the developed technological process, deformation rates of 30 – 80 m /s and heating temperatures of 1000 – 1100°C are optimal, which allow controlling the direction of the joint flow and the processes of joining dissimilar materials.