Vol. 26 No. 1 2024 3 EDITORIAL COUNCIL EDITORIAL BOARD EDITOR-IN-CHIEF: Anatoliy A. Bataev, D.Sc. (Engineering), Professor, Rector, Novosibirsk State Technical University, Novosibirsk, Russian Federation DEPUTIES EDITOR-IN-CHIEF: Vladimir V. Ivancivsky, D.Sc. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Vadim Y. Skeeba, Ph.D. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Editor of the English translation: Elena A. Lozhkina, Ph.D. (Engineering), Department of Material Science in Mechanical Engineering, Novosibirsk State Technical University, Novosibirsk, Russian Federation The journal is issued since 1999 Publication frequency – 4 numbers a year Data on the journal are published in «Ulrich's Periodical Directory» Journal “Obrabotka Metallov” (“Metal Working and Material Science”) has been Indexed in Clarivate Analytics Services. Novosibirsk State Technical University, Prospekt K. Marksa, 20, Novosibirsk, 630073, Russia Tel.: +7 (383) 346-17-75 http://journals.nstu.ru/obrabotka_metallov E-mail: metal_working@mail.ru; metal_working@corp.nstu.ru Journal “Obrabotka Metallov – Metal Working and Material Science” is indexed in the world's largest abstracting bibliographic and scientometric databases Web of Science and Scopus. Journal “Obrabotka Metallov” (“Metal Working & Material Science”) has entered into an electronic licensing relationship with EBSCO Publishing, the world's leading aggregator of full text journals, magazines and eBooks. The full text of JOURNAL can be found in the EBSCOhost™ databases.
OBRABOTKAMETALLOV Vol. 26 No. 1 2024 4 EDITORIAL COUNCIL EDITORIAL COUNCIL CHAIRMAN: Nikolai V. Pustovoy, D.Sc. (Engineering), Professor, President, Novosibirsk State Technical University, Novosibirsk, Russian Federation MEMBERS: The Federative Republic of Brazil: Alberto Moreira Jorge Junior, Dr.-Ing., Full Professor; Federal University of São Carlos, São Carlos The Federal Republic of Germany: Moniko Greif, Dr.-Ing., Professor, Hochschule RheinMain University of Applied Sciences, Russelsheim Florian Nürnberger, Dr.-Ing., Chief Engineer and Head of the Department “Technology of Materials”, Leibniz Universität Hannover, Garbsen; Thomas Hassel, Dr.-Ing., Head of Underwater Technology Center Hanover, Leibniz Universität Hannover, Garbsen The Spain: Andrey L. Chuvilin, Ph.D. (Physics and Mathematics), Ikerbasque Research Professor, Head of Electron Microscopy Laboratory “CIC nanoGUNE”, San Sebastian The Republic of Belarus: Fyodor I. Panteleenko, D.Sc. (Engineering), Professor, First Vice-Rector, Corresponding Member of National Academy of Sciences of Belarus, Belarusian National Technical University, Minsk The Ukraine: Sergiy V. Kovalevskyy, D.Sc. (Engineering), Professor, Vice Rector for Research and Academic Aff airs, Donbass State Engineering Academy, Kramatorsk The Russian Federation: Vladimir G. Atapin, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Victor P. Balkov, Deputy general director, Research and Development Tooling Institute “VNIIINSTRUMENT”, Moscow; Vladimir A. Bataev, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Vladimir G. Burov, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Aleksandr N. Korotkov, D.Sc. (Engineering), Professor, Kuzbass State Technical University, Kemerovo; Dmitry V. Lobanov, D.Sc. (Engineering), Associate Professor, I.N. Ulianov Chuvash State University, Cheboksary; Aleksey V. Makarov, D.Sc. (Engineering), Corresponding Member of RAS, Head of division, Head of laboratory (Laboratory of Mechanical Properties) M.N. Miheev Institute of Metal Physics, Russian Academy of Sciences (Ural Branch), Yekaterinburg; Aleksandr G. Ovcharenko, D.Sc. (Engineering), Professor, Biysk Technological Institute, Biysk; Yuriy N. Saraev, D.Sc. (Engineering), Professor, V.P. Larionov Institute of the Physical-Technical Problems of the North of the Siberian Branch of the RAS, Yakutsk; Alexander S. Yanyushkin, D.Sc. (Engineering), Professor, I.N. Ulianov Chuvash State University, Cheboksary
Vol. 26 No. 1 2024 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Kuts V.V., Oleshitsky A.V., Grechukhin A.N., Grigorov I.Y. Investigation of changes in geometrical parameters of GMAW surfaced specimens under the infl uence of longitudinal magnetic fi eld on electric arc....................................... 6 Saprykina N.А., Chebodaeva V.V., Saprykin A.А., Sharkeev Y.P., Ibragimov E.А., Guseva T.S. Optimization of selective laser melting modes of powder composition of the AlSiMg system................................................................. 22 Gubin D.S., Kisel’ A.G. Features of calculating the cutting temperature during high-speed milling of aluminum alloys without the use of cutting fl uid............................................................................................................................................. 38 EQUIPMENT. INSTRUMENTS Borisov M.A., Lobanov D.V., Zvorygin A.S., Skeeba V.Y. Adaptation of the CNC system of the machine to the conditions of combined processing...................................................................................................................................... 55 Nosenko V.A., Bagaiskov Y.S., Mirocedi A.E., GorbunovA.S. Elastic hones for polishing tooth profi les of heat-treated spur wheels for special applications..................................................................................................................................... 66 Podgornyj Y.I., Skeeba V.Y., Martynova T.G., Lobanov D.V., Martyushev N.V., Papko S.S., Rozhnov E.E., Yulusov I.S. Synthesis of the heddle drive mechanism....................................................................................................... 80 MATERIAL SCIENCE Ragazin A.A., Aryshenskii V.Y., Konovalov S.V., Aryshenskii E.V., Bakhtegareev I.D. Study of the eff ect of hafnium and erbium content on the formation of microstructure in aluminium alloy 1590 cast into a copper chill mold............................................................................................................................................................................ 99 Zorin I.A., Aryshenskii E.V., Drits A.M., Konovalov S.V. Study of evolution of microstructure and mechanical properties in aluminum alloy 1570 with the addition of 0.5 % hafnium........................................................................... 113 Karlina Y.I., Kononenko R.V., Ivantsivsky V.V., Popov M.A., Deryugin F.F., Byankin V.E. Relationship between microstructure and impact toughness of weld metals in pipe high-strength low-alloy steels (research review)..................... 129 Patil N.G., Saraf A.R., Kulkarni A.P Semi empirical modeling of cutting temperature and surface roughness in turning of engineering materials with TiAlN coated carbide tool................................................................................. 155 Sawant D., Bulakh R., Jatti V., Chinchanikar S., Mishra A., Sefene E.M. Investigation on the electrical discharge machining of cryogenic treated beryllium copper (BeCu) alloys........................................................................................ 175 Karlina A.I., Kondratiev V.V., Sysoev I.A., Kolosov A.D., Konstantinova M.V., Guseva E.A. Study of the eff ect of a combined modifi er from silicon production waste on the properties of gray cast iron................................................. 194 EDITORIALMATERIALS 212 FOUNDERS MATERIALS 223 CONTENTS
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 1 4 Elastic hones for polishing tooth profi les of heat-treated spur wheels for special applications Vladimir Nosenko1, а, *, Yuri Bagaiskov 1, b, Alexei Mirocedi 1, c, Alexander Gorbunov 2, d 1 Volzhsky Polytechnic Institute (branch) of Volgograd State Technical University, 43a Engelsa str., Volzhskiy, 404120, Russian Federation 2 Joint Stock Company “Aviation Gearboxes and Transmissions - Perm Motors”, 105g Geroev Khasan St., Perm, 614025, Russian Federation а https://orcid.org/0000-0002-5074-1099, vladim.nosenko2014@yandex.ru; b https://orcid.org/0000-0002-2255-6064, bagaiskov@bk.ru; c https://orcid.org/0009-0001-8252-3299, mirosedy.ae@gmail.com; d https://orcid.org/0009-0001-5780-8508, gorbunov-as@reductor-pm.com Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2024 vol. 26 no. 1 pp. 66–79 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2024-26.1-66-79 ART I CLE I NFO Article history: Received: 15 November 2023 Revised: 07 December 2023 Accepted: 16 January 2024 Available online: 15 March 2024 Keywords: Hone Honing Gearing Recipe Manufacturing technology Morphology Chemical composition Funding: The research was performed under the contract No. Z0111U2023 - 13/46-23 dated 15.02.2023, customer JSC “Aviation Gearboxes and Transmissions - Perm Motors” (JSC “Reductor – PM”) Acknowledgements The authors express their gratitude to A.F. Puchkov, Candidate of Technical Sciences, Associate Professor of the Department of “Chemical Technology of Polymers and Industrial Ecology”, VPI (branch) of VolgGTU, for support and evaluation of the performance of the model mold. ABSTRACT Introduction. The most important component of the technological process of manufacturing of gear wheels of critical products is the operation of teeth honing. Special requirements are imposed on the surface quality of special-purpose gears, where imported abrasive tools were used, the supply of which in modern economic conditions is impossible. Purpose of work: development of formulation, technological equipment and technology of manufacturing of elastic diamond gear hones instead of imported ones for teeth honing of gear wheels of special purpose. Researchmethods. Subject of research are samples of imported elastic gear hones and created domestic analogs. The mechanical properties, morphology and chemical composition of the abrasive (diamond) layer of the working surface of the teeth and the annular gear were determined. The content of chemical elements was controlled in separate points of the surface and by scanning over the area on a scanning electron microscope. The formulation and technology of production of annular gears were determined. Results and Discussion. Designs of molds for forming the abrasive layer and the hub of the gear hone are developed. The peculiarities of morphology of the material of the working layer and the annular gear of the elastic diamond gear hone are revealed. On the basis of the conducted research, domestic analogs of materials of constituent elements of the gear hone are determined. Two manufacturing technologies were considered: pressing and injection molding. Two molds were made to test the technology: a simplifi ed model consisting of two teeth and a round mold. Several methods of manufacturing hone teeth were analyzed: manufacturing of an abrasive layer with diff erent degree of pre-vulcanization, subsequent introduction of gear material and fi nal vulcanization of the whole product. The mechanical properties of the materials of the working abrasive layer and the annular gear were determined. The chemical composition of the components of the hone and the boundary zone are studied. As a result of the conducted research, recommendations on the formulation of the abrasive layer and the annular gear, technology of manufacturing of the gear hone intended for fi nal treatment of teeth of heat-treated spur wheels of special purpose are given. For citation: Nosenko V.A., Bagaiskov Y.S., Mirocedi A.E., Gorbunov A.S. Elastic hones for polishing tooth profi les of heat-treated spur wheels for special applications. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2024, vol. 26, no. 1, pp. 66–79. DOI: 10.17212/1994-6309-2024-26.1-66-79. (In Russian). ______ * Corresponding author Nosenko Vladimir A. D.Sc. (Engineering), Professor Volzhsky Polytechnic Institute (branch) of Volgograd State Technical University, 43a Engelsa str., 404120, Volzhskiy, Russian Federation Tel.: +7 904 403-31-74, e-mail: vladim.nosenko2014@yandex.ru
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 1 2024 Introduction Gear honing is an operation of fi nal processing of tooth profi les of heat-treated cylindrical wheels made of alloyed structural steels with hardness of HRC 50–68 [1, 2, 3]. Gear hone (abrasive shaver) is a gear wheel, the functional rim of which is made of a composite material based on a bond and abrasive materials. The hone hub is usually made of steel or aluminum alloy. The material of the gear hone rim consists of bonding and cutting elements, i.e. abrasive powders of a certain grain size made of various abrasive materials. The use of hones helps to increase the wheel load capacity by 15–20 %, and durability by 1.5– 2.5 times. The most widespread gear hones were obtained when processing hardened gear wheels of 7–9 accuracy degrees. The structural and mechanical characteristics of the composite material of gear hones largely determine its performance [4, 5, 6]. The values of these indicators (tensile and bending strength, toughness, elastic modulus, hardness) depend on the bond material, process methods of hone manufacturing, material and granularity of grinding powders. Abrasive gear hones are made by free casting or injection molding. Epoxy resins and acrylic plastics with various plasticizers and modifi ers are used as binders of abrasive polymer compositions. In addition to hones on rigid bonds with elastic modulus of 3,000–6,000 MPa, elastic hones on polyurethane, acrylicpolyurethane and hydroxyurethane bonds are used, the elastic modulus of which is 1,100–1,200 MPa. Polyurethane SKU-PFL and other urethane-based copolymers give increased elasticity to the hone material [7, 8]. Based on the requirements for processing gears of 7–9 accuracy degrees, the hones are made of various abrasive materials, for example, white electrocorundum with a grain size of F 60–F 90. To ensure the necessary density and strength of the hone material, up to 20 % of grinding powders with a grain size of F 150–F 180 are additionally introduced. Such a tool reduces gear errors, primarily by redistributing its values, for example, fl uctuations in the measuring center-to-center distance, profi le errors, improving the quality of the side surfaces of the teeth, reducing noise in the engagement of machined wheels [3, 9]. In addition to gear hones, which have grinding powders made of classical abrasive materials as cutting elements, diamond gear hones are used for tooth honing. The diamond-bearing layer is made on metal and polymer rubber bonds [4, 10]. The diamond-free base of the hones may be metallic (based on non-ferrous alloys) and rubber (elastic hones). Diamond powders with a main-fraction grain size of 28–20 μm are used for polishing gears of 5–6 accuracy degrees [11, 12]. Diamond tools are widely used in metalworking in roughing [12], fi nishing and precision grinding [13–15]. Certain types of diamond tools provide roughness at the level of polishing operations [16–19]. In the manufacture of automobiles, machine tools, aviation and space engineering, special diamond and abrasive tools have become widely used in the fi nishing operations of high-precision gear wheels [20–22]. For example, imported elastic hones are used to polish tooth surfaces after grinding [8]. The sanctions policy of the Western countries has signifi cantly limited the access of Russian manufacturers to imported tools, and it is impossible to obtain individual items of such tools. These tools include diamond hones for polishing special-purpose gear wheels. The purpose of work is to develop a formulation, technological equipment and technology of manufacturing of elastic diamond gear hones instead of imported ones for teeth honing of gear wheels of special purpose. To achieve this goal, it is necessary to address the following objectives. 1. To determine the intended materials of the abrasive layer and the geared rim based on the results of the literature review, studies of the mechanical properties, morphology and chemical composition of the analyzed hone. 2. To develop and manufacture tooling for molding laboratory specimens of the gear hone. 3. To develop a formulation and manufacturing technology for elastic gear hones for honing the teeth of special-purpose gears based on the results of laboratory studies.
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 1 4 Research Methodology Specimens of imported hones and created analogues were used as objects of research. The mechanical properties, morphology and chemical composition of the diamond and abrasive layer of the gear hone and the annular gear functional surface were investigated. The morphology and chemical composition were studied using a Versa 3DFEI scanning double-beam electron microscope. To study the morphology of the specimens, an Altami CM0870-T optical microscope with a high-resolution camera was also used. Rubber mixtures were made on model L16M rollers. The diameter of the rollers was 100 mm. The rotation speed and the gaps between the rolls were adjustable. The developed compositions of domestic analogues of hones on diamond, abrasive and non-abrasive bases were molded with subsequent vulcanization on a PHG60-212/4 hot press. The specimens were made in the form of discs with a diameter of 50 mm and a height of 6–8 mm and plates of various sizes of the same height. Eight-piece specimens for rupture tests were made from the plates using stamps on the cutting plant. The tests were performed on a RMI-60 laboratory setup. The disc specimens were designed to determine Shore hardness on the LAC-J device. Grinding powders of green silicon carbide 64C and diamond synthetic powders of the AFM grade with a grain size of 28/20 were used as an abrasive material. Results and Discussion The imported specimen of elastic diamond hone consists of a diamond bearing layer (the functional part) and a diamond-free annular gear (hereinafter referred to as the annular gear). The annular gear is attached to a duralumin hub. A fragment of the hone teeth functional surface after straightening with a diamond tool and gear wheel honing is shown in fi gure 1. The hardness of the diamond bearing layer on the side surfaces of the hone teeth is 95–98 Shore units. The hardness of the annular gear material is 85–90 Shore units. The morphology and chemical composition were studied on a tooth fragment of the functional part of the hone, from which cross sections with a thickness of 5 mm were cut. A diamond-bearing layer is allocated along the outer contour of the tooth (fi gure 2, a); the geared rim material lies under it. In the vast majority of the studied sections, the materials have a well-defi ned interface. This is evidenced by the interface condition obtained with a 50× magnifi cation (fi gure 2, b). In the lower part of the tooth of the diamond hone under study, after its dressing, the thickness of the left diamond-bearing layer reaches 2.9 mm and decreases to 2.7–2.6 mm towards the tooth vertex (fi gure 2, a). The thickness of the right diamond bearing layer at the same tooth height is about 2.4 mm. The diff erences in the thicknesses of the diamond-bearing layer between the hone teeth reach 50 % on average. In some photographs, cracks were found in the diamond bearing layer and in the material of the annular gear (fi gure 3 a), diamond bearing layers of a modifi ed structure formed at the site of transition from the tooth root to the main part of the hone (fi gure 3 b, c). It can be assumed that at a temperature of about 170 °C, as a result of the movement of a more mobile liquid material of the annular gear, a part of the diamond bearing layer is captured and transferred to the formed space at the level of the tooth stem. In this case, the thickness of the diamond-bearing layer may vary signifi cantly. In most of the analyzed tooth sections, there are no distortions of the diamond layer. A fairly clear boundary has been formed between the material of the annular gear and the diamond bearing layer at the tooth root. Delamination along the interface is rare and mainly occurs at the root of the hone tooth. Fig. 1. Fragment of the working surface of the hone teeth
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 1 2024 a b Fig. 2. Cross section of a hone tooth at magnifi cation of 15× (a) and 50× (b) The morphology and chemical composition of the hone material were studied using a scanning twobeam electron microscope. Fig. 4 a shows an electronic photograph of the annular gear cross section. Large white spots and smaller dark fragments, which are voids (craters), stand out on the surface. The craters were formed as a result of removal of aluminum powder when the test plate was cut off from the main material of the gear hone. The chemical composition was studied in the Area highlighted by a rectangle. This Area is shown in fi gure 4, b. The chemical composition of the annular gear of hone was determined by scanning the surface area of gray material inclusions (Area 1) and a surface area without visible inclusions (Area 2). Spot analysis was performed in the area of Spot 1 and Spot 2. Regardless of the size of the analyzed surface area, the diameter of the electronic probe was 50 nm. When scanning the surface, the number of measurements (spots) in the selected areas was assumed to be 400. The main chemical element in the X-ray images at Spot 1, Spot 2 and Area 1 is Al. As an example, fi gure 5, a shows an X-ray image obtained by scanning the surface of Area 1. Similar X-ray patterns were obtained at Spot 1 and Spot 2. The composition of the annular gear material was determined on the surface a b c Fig. 3. Cross-section of hone teeth with surface integrity failures
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 1 4 a b Fig. 4. Annular gear cross section (a) and a fragment of the “Area” of this cross section (b) a b Fig. 5. X-ray diff raction patterns of the objects in fi gure 4, b: a – Spot 1; b – Area 2 of Area 2 (see fi gure 4, b). The selected surface area is about 2,600 μm2. An X-ray pattern of the surface is shown in fi gure 5, b. The main chemical element of the analyzed objects is carbon, making almost 57 % (Table). This is followed by chlorine (17 %), sulfur (12 %), oxygen (8 %), zinc (5 %) and magnesium (about 1.6 %). The chemical composition of this material is more consistent with chloroprene rubber. Nitrile butadiene rubber is also close to this chemical composition. There are no fundamental diff erences between the compositions of the diamond bearing layer and the geared rim material. The composition of the diamond bearing layer contains an average of 1.5–2.0 % more sulfur, which is consistent with its higher hardness compared to the hardness of the annular gear material. It can be assumed that the basis of the diamond bearing layer and the annular gear are two materials similar in chemical composition, for example, chloroprene and butadiene-nitrile rubbers, with the addition of various fi llers (binders, softeners, stabilizers, accelerators, vulcanizers, etc.). This rubber with fi llers acts as a bond for the diamond bearing layer and the annular gear material. In the fi rst case, the bond binds and holds diamond or abrasive grains (powders), in the second it binds aluminum powder (GOST 60582022). The aluminum powder in the composition of the annular gear material performs a control function and determines the service life of the diamond hone. The appearance of light spots of aluminum powder inclusions on the dark functional surface of the hone teeth indicates the wear of the diamond bearing layer and the need to replace the abrasive tool. Based on studies of hardness and tensile strength, the optimal range of components of the abrasive layer and annular gear material was determined. Shore hardness of the specimens with an abrasive is 93–95 units, with aluminum powder it is 85–88 units, ultimate strength is 14 MPa and 11 MPa, respectively.
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 1 2024 Chemical composition of the objects (see fi gure 4, b) Object Element Weight, % Atomic, % Error,% Spot 1 O K 3.1 5.1 9.4 Al K 96.9 94.9 1.5 Spot 2 Al K 100.0 100.0 1.6 Area 1 Al K 100.0 100.0 1.6 Area 2 C K 56.8 75.8 10.6 O K 8.4 8.4 12.7 Zn L 5.2 1.3 8.5 Mg K 1.6 1.1 9.6 S K 11.6 5.8 3.2 Cl K 16.7 7.6 3.2 A special mold consisting of two teeth has been developed and manufactured to implement various process schemes for the hone manufacturing. Before forming the abrasive layer (fi gure 6, a), the upper plate 1 was removed from the mold. The mold had the form shown in fi gure 6, b (in the center). The side plate 2 was attached to the mold with screws (see fi gure 6, a). The prepared plates of the abrasive layer material containing the abrasive powder were placed in grooves 4 of the lower plate 3 and distributed evenly on the V-shaped surface of each tooth. The plates were pressed by the upper plate 1 and placed on the table of the press for forming an abrasive layer with a thickness of 3 mm, specifi ed by the design dimensions of the mold. The excess of the molded material enters three derivation canals 5 (see fi gure 6, b). The channels are formed as a result of combining three grooves 6 on the lower plate 3 (see fi gure 6, a) with three of the same slots 7 on the upper plate 1. The same mold, with some modifi cations, is used to make a two-teeth hone model (fi gure 6, b). The preparation for molding consisted in removing the upper forming plate 1. Then, the annular gear material was placed in the mold on the molded abrasive layer and a two-teeth hone fragment was obtained by pressing to study the mechanical, physical and chemical properties of the tool materials. In order to exclude the established fact of displacement of the abrasive layer during molding (see fi gure 3), the preliminary vulcanization of the functional layer was carried out. Then, as mentioned above, а b Fig. 6. A mold for forming a diamond-bearing layer (a) and hone teeth (b)
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 1 4 the required amount of annular gear material was placed in the mold, pressing was performed with fi nal vulcanization. The general view of the two-teeth hone element is shown in fi gure 7, a. When trying to cut off a tooth fragment (end part) with a diamond cutting wheel, the abrasive layer separated from the annular gear material (fi gure 7, b). a b Fig. 7. Two-tooth fragment of a hone after vulcanization (a) and a view of the end part of a hone tooth with prevulcanized abrasive layer (b) The duration of partial vulcanization was reduced by 1.5 and 2.0 times to increase the adhesion strength. The adhesion strength increased, however, with the application of force, and the abrasive layer separated. In this regard, further studies were carried out without preliminary vulcanization of the functional layer. In the left part of the photograph (fi gure 8) there is a functional layer containing grinding powder of green silicon carbide 63C with a grain size of 28/20, with the annular gear material with the addition of aluminum powder in the right part. The interface of the two-layer specimen is homogeneous, without integrity violations, which ensures the necessary strength of adhesion. An experimental mold for the manufacture of a hone model with a 6 mm module, with a number of teeth of 14, was designed and manufactured. The necessary equipment for obtaining gear hone by hot injection molding was selected and manufactured. For preliminary studies, instead of diamond powder, green silicon carbide of the same grain size was used. As a result of the introduction of an additional amount of vulcanizing agents, the following Shore hardness values were obtained: the abrasive layer was 95 units, the annular gear material was about 90 units. The hone model was successfully tested during trial honing of a gear wheel with a diameter of 114 mm and a height of 32 mm. Honing of gear wheels in production conditions is carried out using kerosene-oil cooling lubricants. In this regard, the infl uence of this cooling lubricant on the hone material was investigated. It was found that after 7 days of exposure of hone in a kerosene-oil medium, the hardness of the functional surface of the abrasive layer and the annular gear material did not change. The hone was cut perpendicular to the axis to analyze the condition of the interface between the abrasive layer and the annular gear material. The morphology of the cross-sectional surface of the hone tooth was studied using optical and electron microscopes. The interface of the section (fi gure 9, a) is visually detected. There is a decrease in the thickness of the abrasive layer from the top of the hone tooth to its stem. Fig. 8. Interface between the abrasive layer and the annular gear material
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 1 2024 a b Fig. 9. Cross sections of a hone tooth using green silicon carbide powder as an abrasive material: a – magnifi cation 5×; b – magnifi cation 20× A fragment of the interface between the abrasive layer and the annular gear material is presented separately at 20× magnifi cation (fi gure 9, b). The color background allows drawing a conditional interface between the layers. The base of the material in both components is the same, which ensures strong adhesion between the abrasive layer and the material of the hone annular gear. Aluminum powder was added to the annular gear material to control the abrasive layer wear. The chemical composition near the interface was studied using a scanning electron microscope. In fi gure 10, a, the interface between the abrasive layer and the annular gear material is indicated by vertical line 1. The chemical composition of the treated surface was determined by horizontal line 2 passing from left to right from the area of the abrasive layer into the annular gear material. The main chemical element of the hone material is carbon, which presents in the composition of the abrasive layer and the annular gear. In this regard, carbon registration in the analysis of chemical composition was disabled. a b Fig. 10. Morphology and chemical composition at the interface between the abrasive layer and the gear material The chemical elements determined by X-ray spectral microanalysis in this case are oxygen O, sodium Na, aluminum Al, silicon Si and sulfur S (fi gure 10, b). The content of O, Na and S in the analyzed areas of the hone is the same. In the left part, i.e., in the abrasive layer, there are individual spikes in silicon concentration, which indicates the presence of crystals of an abrasive material (silicon carbide). Due to the fact that the scanning route was laid excluding contact with aluminum powder, aluminum was not detected in the section of the interface under consideration. The results of the X-ray spectral analysis are consistent with the previously obtained data and indicate a uniform distribution of chemical elements in the material of various parts of the hone, except for aluminum
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 1 4 and silicon. The increased aluminum content is due to the presence of aluminum powder in the annular gear material, the increased silicon content in the abrasive layer material is due to the presence of silicon carbide crystals. Conclusion 1. Based on the results of a literature review and the results of a study of the chemical composition of fragments of imported hone, it was found that chloroprene and butadiene-nitrile rubbers, the composition of which is close to the imported analog, may be used as a hone material. 2. Studies of the mechanical properties of laboratory specimens showed that these materials, with the addition of various fi llers (humidifi ers, binders, stabilizers, softeners, vulcanizing agents, accelerators, etc.), provide the necessary Shore hardness; for an abrasive layer, this value is 93–95 units, for a annular gear of hone it is 85–88 units, tensile strength is 14 MPa and 11 MPa, respectively. 3. To refi ne the formulation and production technology of the imported hone domestic analogue, a two-teeth laboratory mold was made, which allows performing the following operations: molding and heat treatment of the abrasive layer, joint molding and heat treatment of the abrasive layer and the annular gear. 4. It is established that the preliminary vulcanization of the abrasive layer has a signifi cant eff ect on the strength of its adhesion to the annular gear material: with an increase in the degree of vulcanization, the adhesion force decreases. In this regard, the joint vulcanization of the abrasive layer and the annular gear is adopted in the technological process. 5. The required thickness of the abrasive layer is obtained by rolling followed by profi ling in a mold without vulcanization. Further technology is implemented by injection molding and pressing methods followed by vulcanization. 6. An experimental mold for the manufacture of a hone model with a 6 mm module, with a number of teeth of 14, is designed and manufactured. The following Shore hardness values were obtained: the abrasive layer was 95 units, the annular gear material was about 90 units. The hone model was successfully tested during trial honing of a gear wheel. 7. After seven days of exposure in a kerosene-oil medium used in production conditions for honing operations, the hardness of the abrasive layer of the geared hone and the annular gear material did not change. 8. The developed formulation of elastic gear hone and its manufacturing technologies are accepted for testing under production conditions. References 1. Kalashnikov A.S. Zubokhoningovanie zubchatykh koles [Technology of a gear-tooth honing of cylindrical gears]. RITM: Remont. Innovatsii.Tekhnologii.Modernizatsiya, 2013, no. 10 (88), pp. 22–29. (In Russian). 2. Kalashnikov A.S., Morgunov J.A., Kalashnikov P.A. Osobennosti tekhnologii zubokhoningovaniya tsilindricheskikh koles [Technology features of honing of cylindrical gears]. Spravochnik. Inzhenernyi zhurnal = Handbook. An Engineering journal, 2014, no. 6 (207), pp. 3–9. DOI: 10.14489/hb.2014.06.pp.003-009. 3. KalashnikovA.S.,MorgunovYu.A.,VasilyevA.N., KaravanovaA.G. Chistovaya obrabotka zub’ev zakalennykh tsilindricheskikh peredach zubokhoningovaniem [Finishing treatment of the teeth of hardened cylindrical gears by tooth honing]. Spravochnik. Inzhenernyi zhurnal = Handbook. An Engineering journal, 2022, no. 8, pp. 11–16. DOI: 10.14489/hb.2022.08.pp.011-016. 4. Graf W. Shlifovanie i polirovanie zubchatykh koles [Grinding and polishing of gears]. RITM mashinostroeniya = Rhythm of machinery, 2016, no. 6, pp. 27–28. (In Russian). 5. Karavanova A.G., Kalashnikov A.S. Razlichie rezul’tatov protsessov obrabotki zubchatykh koles metodami khoningovaniya, shlifovaniya i polirovaniya iskhodya iz vyyavlennykh znachenii mikronerovnostei obrabatyvaemoi poverkhnosti [The diff erence in processing of gear wheels by honing, grinding and polishing methods based on the identifi ed values of surface microroughness]. Nauka i biznes: puti razvitiya = Science and Business: Development Ways, 2020, no. 11 (113), pp. 23–27.
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