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| Development stages for control water - air hardening of dies |
| Selecting the characteristic zone on dies surface Selecting the rate for cooling of dies surface Mathematical simulation of quenching regime Controlling water - air hardening of dies Selftempering |
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| The unit operating at the Minsk automobile plant performs quenching dies sizes from 100x100x100mm to 1500x1000x1000mm after furnace heating. |
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| · Overall dimensions of the unit: 6200x2000x3500mm · Dimensions of the working zone: 2000x2500x2000mm · Number of nozzles: 4 panels with 10 nozzles in each · Water flow rate: 0.86 m3/h · Airflow rate: 92.000 m3/h · Water pressure: 0.4 MPa · Air pressure: 0.4 MPa · Weight of the parts: up to 8000kg |
| Inserts of hammer dies made of steel NI-13 and 45xMFTR were subjected to thermo processing by the water-air mixture. As a result, the desired hardness was achieved without any micro cracks. An initial lot of the inserts of hammer dies tested under working conditions has demonstrated the 2-3 times fold higher longevity as compared to the lifetime of the analogous dies quenched in oils. At the same time cost for heat treatment have reduces by 1,5-2 times. |
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| © 2002 Technology of Controlled Water-Air Quenching. All rights reserved. |
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| At present we developed the three types of installations for hardening hammer inserts: 1. CWAH-500 (for details with the sizes up to 0.5m) 2. CWAH-8000 (for details with the sizes up to 1.5m) 3. CWAH-16000 (for details with the sizes up to 2.4m) - It is possible to be acquainted with activity of these installations on the Minsk automobile plant (the first installation CWAH-8000 works since September 1996), on the Minsk tractor plant (the installation CWAH-8000 works since June 2000, the contract on delivery in 2001 of the installation CWAH-500 is signed), at Joint Stock Company "KurganMashZavod" (Russia), the launching of the installation CWAH-8000 is intended in April 2001, the launching of the installation CWAH-500 in June 2001). - In the near future it is planning delivery of the installation CWAH-16000 on the Belarus automobile plant (BelAZ), SWAH-8000 on Yaroslavl motor plant (Russia). |
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| · Technology of the controlled water-air cooling is intended for substitution traditional quenching media (oils, aqueous solutions of polymers, salts, alkali, etc.) for tempering a parts complicated geometry and for obtaining new regimes that are not possible to implement by the existing quenching methods. · A distinctive feature of the controlled quenching technology is thermo processing a parts complicated geometry in zones which is most typical for quenching dies. |
| · The suggested method permits a die impression and a shank to be cooled at different rates thus ensuring the prescribed hardness in two zones. · The possibility is provided to implement the process of self-tempering by transferring the heat from internal warm layers to the external ones to equalize the temperature over the part section and to cool it further in air. |
| Process control scheme |
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| The quenching time of one die may vary from 2 to 20 min depending of it size. |