Vol. 26 No. 4 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. 4 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. 4 2024 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Manikanta J.E., Ambhore N., Shamkuwar S., Gurajala N.K., Dakarapu S.R. Investigation of vegetable-based hybrid nanofl uids on machining performance in MQL turning........................................................................................... 6 Dama Y.B., Jogi B.F., Pawade R., Kulkarni A.P. Impact of print orientation on wear behavior in FDM printed PLA Biomaterial: Study for hip-joint implant...................................................................................................................... 19 GrinenkoA.V., ChumaevskyA.V., Sidorov E.A., Utyaganova V.R.,AmirovA.I., Kolubaev E.A. Geometry distortion, edge oxidation, structural changes and cut surface morphology of 100mm thick sheet product made of aluminum, copper and titanium alloys during reverse polarity plasma cutting...................................................................................... 41 Somatkar A., Dwivedi R., Chinchanikar S. Comparative evaluation of roller burnishing of Al6061-T6 alloy under dry and nanofl uid minimum quantity lubrication conditions............................................................................................... 57 Karlina Yu.I., Konyukhov V.Yu., Oparina T.A. Assessment of the quality and mechanical properties of metal layers from low-carbon steel obtained by the WAAM method with the use of additional using additional mechanical and ultrasonic processing..................................................................................................................................................... 75 EQUIPMENT. INSTRUMENTS Yusubov N.D., Abbasova H.M. Systematics of multi-tool setup on lathe group machines............................................... 92 Toshov J.B., Fozilov D.M., Yelemessov K.K., Ruziev U.N., Abdullayev D.N., Baskanbayeva D.D., Bekirova L.R. Increasing the durability of drill bit teeth by changing its manufacturing technology......................................................... 112 Pospelov I.D. Investigation of the distribution of normal contact stresses in deformation zone during hot rolling of strips made of structural low-alloy steels to increase the resistance of working rolls..................................................... 125 Ablyaz T.R., Blokhin V.B., Shlykov E.S., Muratov K.R., Osinnikov I.V. Manufacturing of tool electrodes with optimized confi guration for copy-piercing electrical discharge machining by rapid prototyping method.......................... 138 MATERIAL SCIENCE Shubert A.V., Konovalov S.V., Panchenko I.A. A review of research on high-entropy alloys, its properties, methods of creation and application.................................................................................................................................................. 153 Syusyuka E.N., Amineva E.H., Kabirov Yu.V., Prutsakova N.V. Analysis of changes in the microstructure of compression rings of an auxiliary marine engine.......................................................................................................... 180 Dudareva A.A., Bushueva E.G., Tyurin A.G., Domarov E.V., Nasennik I.E., Shikalov V.S., Skorokhod K.A., Legkodymov A.A. The eff ect of hot plastic deformation on the structure and properties of surface-modifi ed layers after non-vacuum electron beam surfacing of a powder mixture of composition 10Cr-30B on steel 0.12 C-18 Cr-9 Ni-Ti............................................................................................................................................................................. 192 Boltrushevich A.E., Martyushev N.V., Kozlov V.N., Kuznetsova Yu.S. Structure of Inconel 625 alloy blanks obtained by electric arc surfacing and electron beam surfacing........................................................................................... 206 Sablina T.Y., Panchenko M.Yu., Zyatikov I.A., Puchikin A.V., Konovalov I.N., Panchenko Yu.N. Study of surface hydrophilicity of metallic materials modifi ed by ultraviolet laser radiation........................................................................ 218 EDITORIALMATERIALS 234 FOUNDERS MATERIALS 243 CONTENTS
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 4 4 Increasing the durability of drill bit teeth by changing its manufacturing technology Javokhir Toshov1, a, Doniyor Fozilov 2, b, Kassym Yelemessov 3, c, Ulugbek Ruziev 2, d, Dovudjon Abdullayev 2, e, Dinara Baskanbayeva 3, f, *, Lala Bekirova 4, g 1 Tashkent State Technical University, 2, University st., Tashkent, 100095, Republic of Uzbekistan 2 JSC “Scientifi c and Production Association” Almalyk MMC”, 1 V. Gaidarova st., Chirchik, 111700, Republic of Uzbekistan 3 K.I. Satbayev Kazakh National Research Technical University, 2 Satbaev st., Almaty, 050013, Republic of Kazakhstan 4 Azerbaijan State Oil and Industry University, 34 Azadliq Ave., Baku, AZ1010, Azerbaijan a https://orcid.org/0000-0003-4278-1557, j.toshov@tdtu.uz; b https://orcid.org/0009-0005-6362-8326, fozilovdoniyor81@gmail.com; c https://orcid.org/0000-0001-6168-2787, k.yelemessov@satbayev.university; d https://orcid.org/0009-0008-2371-3085, u.ruziev@agmk.uz; e https://orcid.org/0009-0005-6362-8326, dn.abdullaev@agmk.uz; f https://orcid.org/0000-0003-1688-0666, d.baskanbayeva@satbayev.university; g https://orcid.org/0000-0003-0584-7916, lala.bakirova@asoiu.edu.az 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. 4 pp. 112–124 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2024-26.4-112-124 ART I CLE I NFO Article history: Received: 22 August 2024 Revised: 10 September 2024 Accepted: 17 September 2024 Available online: 15 December 2024 Keywords: Drill bits Tungsten-cobalt alloys Manufacturing Pin bit Hard rocks Performance testing Funding This research was funded by Science Committee of the Ministry of Science and Higher Education of the Republic of Kazakhstan, grant number IRN BR18574141. ABSTRACT Introduction. The development of the mining industry requires increasing the durability and safe tool performance life. For bits of mining drilling machines, this problem is often solved by improving the material of the teeth of these bits. The paper presents the results of a study on the development of a technology for the manufacture of hard-alloy drill bits with increased wear resistance and testing of prototypes when drilling hard rocks. Changes in technology have led to changes in the shape of the tooth. Also, purer tungsten powder was used as the initial component. Research methods. The paper studies carbide teeth of bits manufactured at JSC Almalyk Mining and Metallurgical Combine using standard and modifi ed technology. Its structure and chemical composition were studied. Results and discussion. New methods for performing technological operations for the manufacture of carbide teeth (pins) and steel pin bits are developed and mastered. Tungstencobalt teeth were manufactured using VK10KS (90 %W; 10 % Co) hard alloy, produced using tungsten carbide powder synthesized by carbidization of purifi ed tungsten powder. The shape of the tooth surface was changed from ballistic to semi-ballistic. Metallic cobalt powder was used as a binder. Pin bits of the KNSh40×25 type are made of 0.35 C-Cr-Mn-Si steel. Tests of experimental bits were carried out at several mines, as a result of which its suitability for drilling rocks with a hardness of f` = 14–18 was established. The results of industrial operation showed that the durability of the teeth of bits manufactured by JSC Almalyk Mining and Metallurgical Combine is not signifi cantly inferior to bits from European manufacturers. At the same time, the cost of such bits is several times lower. For citation: Toshov J.B., Fozilov D.M., Yelemessov K.K., Ruziev U.N., Abdullayev D.N., Baskanbayeva D.D., Bekirova L.R. Increasing the durability of drill bit teeth by changing its manufacturing technology. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2024, vol. 26, no. 4, pp. 112–124. DOI: 10.17212/1994-6309-2024-26.4-112-124. (In Russian). ______ * Corresponding author Baskanbayeva Dinara D., Ph.D. (Engineering), Deputy Director K.I. Satbayev Kazakh National Research Technical University, 2 Satbaev st., 050013, Almaty, Republic of Kazakhstan Tel.: +7 701 861 5162, e-mail: d.baskanbayeva@satbayev.university Introduction The mining industry in Central Asia is actively developing due to the presence of rich natural resources. Central Asian states, including Uzbekistan, Kazakhstan, Tajikistan, Kyrgyzstan and Turkmenistan, are actively developing the mining industry in an eff ort to increase production and attract foreign investment [1]. One of the key areas of the mining industry development is the extraction and the processing of rare
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 4 2024 earth metals. Rare earth metals play an important role in the manufacture of high-tech products, such as electronics, batteries and renewable energy equipment [2–5]. Increasing the mineral extraction requires active improvement of both equipment and machinery, as well as extraction tools. Rotary-percussive drilling is a combined type of drilling that combines rock cutting with the application of percussive loads. In this type of drilling, the rock cutting tool is subjected to torque, static feed force and impacts of a certain frequency and force. In some geological conditions, rotary-percussive drilling turns out to be more productive than rotary and percussive drilling separately. This explains its wide application in various mining operations [6, 7]. Effi cient rock destruction during rotary-percussive drilling with carbide bits is achieved by an optimal selection of the carbide composition, the tool size, the geometry of cutters, its location along the bit face, the well-organised fl ushing system and properly calculated parameters of the drilling mode [8–10]. In pin drills, hard alloys are used as the material for the cutting teeth, usually tungsten-cobalt alloys VK6 (94 %W; 6 % Co) and VK8 (92 %W; 8 % Co). These carbide materials have proven to be reliable and relatively inexpensive to use. Bits of such type can be exploited in the rocks up to the ninth category of drillability [11]. Bit wear resistance in operation depends on geological and technical drilling conditions: hardness, abrasiveness, fracture density, discontinuity of rocks; rotation speed, diameter of the bit and axial load; a depth and curvature of the borehole, serviceability of the drilling machine [12–15]. However, the hardness and bending strength of carbide cutters, as well as the quality of manufacturing and the assembly of the pin bit, are of decisive importance. A signifi cant share of such tools is produced in European countries and has a high cost. Within the framework of the AlmalykMMC JSC enterprise (Uzbekistan), rock-cutting bits are produced at a signifi cantly lower cost. At the same time, the resistance and durability of such bits are lower than those of European analogues. The purpose of this work is to increase the durability of drill bit teeth by improving the manufacturing technology of this tool Research Methodology This work was carried out in three stages. At the fi rst stage, an analysis of the causes of the destruction of the bits manufactured by Almalyk Mining and Metallurgical Company JSC was carried out. At the second stage, based on the results obtained, the technology of bit teeth manufacturing was changed, and the samples, obtained by the new technology, were investigated. At the third stage, the comparative testing of bit samples manufactured using the improved technology and European analogues of the Atlas Copco company (Sweden) were carried out. The research work was performed on the basis of the Scientifi c and Production Association for the production of rare metals and hard alloys of the Almalyk Mining and Metallurgical Company JSC (NPO AGMK). The research was focused on the development of the technology to manufacture the KNSh 40×25 mm type drill bits with seven inserted pins-tooths that are similar to Atlas Copco drill bits (Sweden). Prototype bits were manufactured using tungsten-cobalt alloy carbide teeth. The teeth were produced at NPO AGMK. Structural studies were carried out, using a Carl Zeiss Axio Observer Z1m light microscope and a Carl Zeiss EVO 50 XVP scanning electron microscope (Jena, Germany). The phase composition was studied using an ARL X’TRA X-ray diff ractometer (Thermo Fisher Scientifi c, Waltham, MA, USA) in the CuKα radiation. For metallographic analysis of the bit tooth surface, the visual-optical method was employed, using a Carl Zeiss Axio Observer A1m microscope.
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 4 4 Results and Discussion Determination of the causes of destruction of the teeth of bits manufactured using standard technology The experimental testing of the fi rst samples of KNSh 40×25 mm roller cones was characterised by low wear resistance during penetration, compared to that of the imported samples produced by Atlas Сорсо (Sweden). Fig. 1 shows a sample of KNSh 40×25 mm bit after testing for penetrating granite to a drilling depth of 18 cm (a), and an enlarged image of the porous surface of the tooth with depressions forming the so-called “reptile skin” surface (b). a b Fig. 1. Seven-cone drill bit type KNSh40×25 manufactured by NPO, after operational tests during drilling of granite rock; drilling depth 18 cm (a); the condition of the surfaces of the teeth of the crown, characterized by porosity with depressions known as the formation of the “reptile skin” surface (b) Fig. 2 presents an enlarged image of the surface area at the boundary of the tooth wear area with the tooth surface before wear, which shows that along the boundary there is a separation of whole clusters of grains of the hard VK (WC-Co) alloy as a result of wear. The “reptile skin” type surface is the result of maximum tensile stresses occurring at individual points of contact with the asperity of the rock. Fig. 3 provides a schematic example, explaining the mechanism of crack formation on the tooth surface. According to the source, a protruding part of the rock is pressed into the tooth surface, creating localised stress on its surface. When this procedure is repeated several times, small cracks aggregate, eventually forming a “reptile skin” structure. Fig. 2. Cross-section of the boundary of the surface of the tooth wear area with the tooth surface before wear: left – original surface; right – surface as a result of wear
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 4 2024 Fig. 3. The mechanism of formation of “reptile skin” In order to establish the reasons for the low wear resistance of the experimental bits, the AGMK NPO carried out the research, aimed at developing optimal methods for manufacturing tungsten-cobalt teeth, its fi rm fi xation in the bit grooves and improving the technology of its assembly. According to literature sources [16, 17], the materials can be separated from the surfaces of carbide teeth in several ways: ● grinding of grains of the VK (W-Co) hard alloy and separation of fragments; ● separation of whole grains or parts of grains that lose its ability to be retained in the structure; ● grinding the mixture: VK (W-Co) hard alloy /rock binder and separation of fragments; ● tribochemical wear, scraping off corroded or oxidised surface layers of VK (W-Co) hard alloy; ● separation of composite fragments of VK (W-Co) grain groups together with the binder. A study of the microstructure of tungsten-cobalt teeth samples of the fi rst experimental batches showed that one of the reasons for the formation of a porous structure with depressions, prone to the formation of pits, cracks and chips, when the teeth are exposed to roughness of rocks, was the large size of tungsten carbide grains. The large size of tungsten grains is obtained as a result of using conventional metallic tungsten powder containing undesirable impurities of calcium, silicon, iron and Sulphur. Fig. 4 demonstrates the microstructure of a conventional sample of hard VK10 (90 %W; 10 % Co) alloy, the elemental composition of which revealed a signifi cant content of impurities that negatively aff ect the physical and mechanical properties of the alloy (Fig. 5). Fig. 6 shows the microstructure of the junction surface of a sample of conventional hard alloy VK10 (90 %W; 10 % Co). The hard alloy can be seen to be characterised by the presence of areas of inhomogeneity in the form of clusters of large spherical formations, as well as clearly foreign particles, exposed on the fracture surface of the VK10 (90 %W; 10 % Co) sample (Fig. 7). This explains the cause of the fracture. The areas of inhomogeneity and the presence of grains of foreign impurities negatively infl uence the bending strength, hardness, impact toughness and other physical and mechanical properties of the hard alloy VK10 (90 %W; 10 % Co), which should ultimately determine the operational wear resistance of manufactured carbide teeth. Fig. 4. Morphological features of the microstructure of a conventional sample of hard alloy VK10 (90 %W; 10 % Co)
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 4 4 Fig. 5. Results of elemental analysis of a section of the microstructure of a sample of conventional hard alloy VK10 (90 %W; 10 % Co) Fig. 6. Cleavage surface of a sample of conventional hard alloy VK10 (90 %W; 10 % Co) Fig. 7. Fracture surface of a sample of conventional hard alloy VK10 (90 %W; 10 % Co) Improvement of the technology for producing bit teeth To achieve high purity and homogeneity of the VK10 (90 %W; 10 % Co) alloy for drilling bit teeth, the technological parameters for obtaining high-purity tungsten metal powder were developed and tested. For this purpose, the technology of obtaining initial tungsten trioxide of high purity was developed. The description of the technology was provided in earlier works of the authors [18, 19]. Fig. 8 presents a micrograph of the tungsten trioxide powder, consisting of homogeneous prismatic crystals. The elemental composition is characterised by the presence of tungsten and oxygen. The ratio of these elements corresponds to the stoichiometry of the trioxide. Fig. 9 shows a micrograph of crystals of the tungsten metal powder, obtained from pure tungsten trioxide. Fig. 9 provides the results of the elemental analysis of the crystals of the obtained tungsten metal powder. Fig. 10 shows the results of the elemental analysis of a sample of synthesised pure metallic tungsten powder, confi rming its high purity. Pure metallic tungsten powder was used to obtain tungsten carbide by the method of carbidization, using graphite powder according to the technology of NPO AGMK. The pure metallic tungsten powder with the W content of more than 99.80 %, i.e. corresponding to the KS grade, was used. The reduction was carried out according to the mode of obtaining its carbide powder, with an average Fischer grain size
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 4 2024 Fig. 8. Tungsten trioxide powder crystals; results of elemental analysis of tungsten trioxide powder Fig. 9. Micrograph of pure tungsten metal powder obtained from pure tungsten trioxide of 12.0–20.0 μm. The process of obtaining the hard alloy consisted of grinding a mixture of metallic tungsten and graphite powders in a mill with alcohol, evaporating the pulp, sifting, mixing with a plasticizer, pressing the teeth, drying and hydrogen sintering. For pressing the teeth, special hard alloy punches, made of the VK20 (80 % W, 20 % Co) alloy, were fabricated to increase the pressing pressure to achieve its high density, uniformity, strength and wear resistance.
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 4 4 Fig. 10. Results of elemental analysis of the synthesized sample of pure tungsten metal powder During the tooth pressing stage, a number of issues were addressed to eliminate the tendency of pressing cracks, resulting from the increased dispersion of the pressing powder [20]. Characteristic cracks were formed perpendicular to the pressing vector, due to the delamination of the pressing powder, as a result of the so-called “spring eff ect”, associated with the occurrence of a pressure gradient. Fig. 11 demonstrates delamination cracks occurring during the pressing of teeth, made of highly dispersed pressing powders. When loading the upper working surface of the ballistic tooth with the upper punch, a horizontal annular layer of compacta was found on the lateral cylindrical surface, located near the upper spherical surface. The tooth surface, formed in contact with the upper punch, was found to be characterised by the formation of a porous structure with depressions, that is, with the formation of the “reptile skin”. In order to prevent the occurence of delamination cracks in the area of the upper working part of the tooth, where the greatest strength and wear resistance are required, and to exclude the formation of the “reptile skin”, the tooth shape was changed from ballistic to semi-ballistic [21, 22]. As a result of changing the shape, previously subjected to the specifi ed press defects, the upper surface of the tooth came into contact with the lower punch. In this case, the upper punch with the modifi ed surface shape formed the lower part of the tooth. Fig. 11 shows the samples of stamped semi-fi nished products of ballistic and semi-ballistic teeth. Subsequent operational tests confi rmed the correctness of changing the tooth shape to semi-ballistic. Figs. 12 and 13 present the condition of tooth face surfaces when manufacturing in ballistic and semiballistic shapes. The physical and chemical parameters of carbide tooth samples, sintered in a hydrogen furnace under various modes, were tested [23, 24]. The test results showed the compliance of the obtained tooth samples with the normative requirements for the VK10-KC alloy (Table 1). Compared to Atlas Copco (Sweden) bits, the hardness and the grain size diff er by no more than 2.5 %. The hardness of the teeth on the Atlas Copco tool is 88.3 HRA. This is almost identical to the hardness of the teeth, obtained by the developed technology. The average grain size is also almost the same; for Atlas Copco teeth it is 4.1 μm. This also does not diff er signifi cantly from the grain size of the teeth obtained using the developed technology.
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 4 2024 Fig. 11. Areas of localization of delamination cracks in hard alloy. Ballistic and semi-ballistic teeth a b Fig. 12. Working surfaces of teeth of ballistic (a) and semi-ballistic (b) shapes a b Fig. 13. Sample of working (a) and reverse (b) surfaces of a semi-ballistic carbide tooth
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 4 4 Ta b l e 1 Results of comparative tests of physical and chemical properties of carbide teeth sintered under diff erent conditions Analysed parameters Properties of teeth sintered by method 1 Properties of teeth sintered by method 2 Technical requirements for the VK10 (90 %W; 10 % Co) alloy Density, g/cm3 14.55 14.51 14.43–14.63 Hardness, HRA 87.8 87.8 87.4–88.2 Coercive force, E 87 80 70–90 Average grain size, μm 4.3 4.2 Not regulated Microstructure Equiaxial grain structure Equiaxial grain structure Homogeneous, without coarse grains and cobalt clusters Ctotal , % 5.40 5.52 5.46–5.54 Comparative tests of bits manufactured using diff erent technologies A 3D model of a pin crown and a programme for its manufacture on a fi ve-axis CNC machine (SNKexl 80) were developed for the production of steel crown bodies. The experimental crowns were made of 0.35 C-Cr-Mn-Si steel with the subsequent hardening and grinding up to Ra of 1.6. The fi nal assembly of KNSh 40×25 bits was performed by the cold pressing of teeth, sharpened to a tooth cone angle of 39 degrees. Experimental batches of KNSh 40×25 bits were manufactured for production testing and underwent operational tests at several mines. Several batches of experimental KNSh 40×25 bits were tested at Kyzyl-Olma mines of the Angren Mining Administration, when drilling rocks with a hardness of f` = 14–15, with a drilling result of 48.2 meters, as well as for rocks with f` = 12–16 with a result of 46.3 meters, with wear of 10–15 %. The bits were also tested while drilling the rocks a hardness of f`=14-17 in conditions of the Kauldy mine with an average result of four penetrations of 49.5 meters. Fifteen KNSh 40×25 bits were also tested at the Chadak mine in adits with a rock hardness of f` =16–18, the drilling results ranged from 47 to 58 meters. The certifi cates of industrial tests for the suitability of KNSh 40×25 drill bits manufactured at NPP for work at the Angren, Kauldi and Chadak mines were received. The work performed on the industrial operation of the experimental bits showed that its durability is inferior to the bits manufactured by Atlas Copco (Sweden) by no more than 14-17 %. When mastering the production of hard-alloy pin bits (KNSh 40×25) at Almalyk MMC JSC enterprise, it is expected that a signifi cant annual economic eff ect will be obtained due to its lower cost in comparison with Atlas Copco bits (Sweden). Conclusion Based on the results of the conducted research, the main reasons for the rapid failure of the drill bit teeth produced by NPO AGMK were identifi ed. Studies showed that the main reasons for its destruction are a poor structure (coarse grains and the presence of microdefects). Also, the unsuccessful shape of the tooth surface signifi cantly reduces the resistance. The work carried out to optimize the technology for manufacturing the teeth of the bits made it possible to signifi cantly increase its durability. For manufacturing, a purer tungsten powder of lower dispersion was used, the shape of the tooth surface was optimized to semi-ballistic. Changes were also made to the sintering mode and subsequent agening of the teeth. As a result, an improved technology for manufacturing teeth from hard alloy VK10-KS was developed. The teeth manufactured using the developed technology showed comparable resistance to the teeth manufactured by European manufacturers (Atlas Copco, Sweden). At the same time, the cost of bits with teeth manufactured using the NPO AGMK technology is signifi cantly lower.
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