Volume 03 Issue 10-2023
260
International Journal of Advance Scientific Research
(ISSN
–
2750-1396)
VOLUME
03
ISSUE
10
Pages:
260-269
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
A
BSTRACT
The improvement in the processing of wires made of copper materials in drawing machines is inextricably
linked with the use of hard alloys. This leads to a significant increase in the mechanical properties of the
device and the stretching performance. Nowadays, stretching is one of the main requirements of wire
production to ensure their resistance to corrosion by increasing the hardness of the equipment. In this
article, the causes, appearance and ways of eliminating stretching equipment are given.
K
EYWORDS
Deformation, hard alloy, roll, elongation, corrosion, construction, defect, performance, tungsten, taper.
I
NTRODUCTION
In the era of a rapidly growing market economy,
the need to focus on improving product quality
and increasing competitiveness in manufacturing
enterprises is increasing day by day, because,
without these main factors, it is impossible to
introduce
products
that
meet
global
requirements and high economic efficiency of
production. Taking this into account, the demand
for existing technologies and equipment in
production increases the quality of products in
any production condition, and the production of
products that meet export requirements is given
great importance. It should be mentioned that the
increase in product quality directly leads to an
increase in the cost of the product. Reducing the
cost of the product and increasing its quality is
Journal
Website:
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Original
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4.0 licence.
Research Article
ANALYSIS OF FACTORS AFFECTING THE MANUFACTURING
TECHNOLOGY AND CONSUMPTION OF TOOLS USED IN
WIREDRAWING MACHINES
Submission Date:
October 20, 2023,
Accepted Date:
October 25, 2023,
Published Date:
October 30, 2023
Crossref doi:
https://doi.org/10.37547/ijasr-03-10-41
Boburbek Tojiyev
Phd Student, Fergana Polytechnic Institute, Fergana, Uzbekistan
Volume 03 Issue 10-2023
261
International Journal of Advance Scientific Research
(ISSN
–
2750-1396)
VOLUME
03
ISSUE
10
Pages:
260-269
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
one of the main requirements of the current
market economy [1]. Reducing the cost of the
product depends on the material properties of the
tool used in production, the manufacturing
technology, the processing conditions and the
correct selection of the structural parameters of
the tool.
Picture 1. Die construction.
1- input part, 2- working part, 3- sizing part,
Part 4 of the output
Today, the most popular in the world market of
products made of metals are products made of
steel and copper wire. One of the most important
and labour-intensive stages of production is the
wire drawing process. Pulleys used in the
drawing process are used as wire drawing tools
on drawing machines. The most common
materials for the production of stretching tools
today are hard alloys based on tungsten carbide
[2].
The construction of the tool used for stretching
cylindrical wires in drawing machines is
presented in Figure 1 [3]. The tool consists of 4
parts.
1.
The entrance part serves for correct and
proper penetration of the wires and lubrication of
the next part.
2.
The working part - plastic and elastic
deformations take place. Metals are most affected
in this part.
3.
Sizing part - provides the size and shape of
the product.
4.
Output part - serves for output.
One of the main factors that directly affect
productivity during stretching is the wear and
quality of the stretching tool, i.e. the roller.
Therefore, the quality of the wires mainly
determines the economic indicators of stretching
and the characteristics of the wire. Worn or
damaged fibres create defects that can cause
problems in the stretching process.
Volume 03 Issue 10-2023
262
International Journal of Advance Scientific Research
(ISSN
–
2750-1396)
VOLUME
03
ISSUE
10
Pages:
260-269
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
Thus, the fulfilment of the requirements for
increasing the processing productivity of the
drawing machines, reducing the product cost and
ensuring the high quality of the transferred wire
is inextricably linked with the problem of the
durability of the drawing tools.
The main disadvantages of hard alloy tools used
in drawing machines;
1.
Cracks;
2.
Release of hard alloy attachment;
3.
Disintegration of the attachment surface of
the hard alloy;
4.
Separation of hard alloy elements;
5.
Complete separation of hard alloy
elements;
6.
Deep scratch of hard alloy part;
7.
Circumferential wear of the die part;
8.
One-sided defect;
9.
Cracking of hard alloy material;
10.
Formation of an oxide layer on the
working surface of the wire, etc.
Materials and methods
Stretching is to prevent premature wear and
failure of tools
it is necessary to analyze the reasons for the
appearance of defects in the stretching process
and the methods of their elimination.
The percentage distribution of the main defects
that occur during stretching is shown in Figure 2.
Main defects
of rollers
Volok's various
cracks
Volok's one-
sided
emergent
eating
Deep scratches
on the working
part of the roller
Formation of
an oxide layer
on the
working part
Decompositio
n of the
attachment
surface of
Circumferenti
al wear of the
volok part
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(ISSN
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VOLUME
03
ISSUE
10
Pages:
260-269
SJIF
I
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FACTOR
(2021:
5.478
)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
Figure 2. Percentage distribution of the main defects that occur during stretching
Cracks are caused by the failure of crystal lattices
of solid alloy materials in the working part of the
roller, perpendicular or along its axis. The rollers
used in the stretching process are made of very
strong materials. This means that they are prone
to cracking under the influence of heat and
mechanical forces.
Mechanical forces always occur in the direction of
stretching and therefore cause only certain types
of cracks. Heat gain is less pronounced, so it can
cause various types of cracks. Most cracks caused
by overheating are usually random in size and
orientation. Due to such cracks, stresses appear,
and then mechanical forces cause the cracks to
grow rapidly. Cracks can occur in the longitudinal
direction of the tool and in the transverse
direction.
Longitudinal cracks spread through the entire
roll. If at least one of these cracks is detected, it
can be assumed that there is at least one crack in
the roller. Such cracks occur when the force
required to deform the wire is greater than the
strength of the wire material and its casing. In
some cases, it is necessary to redesign the roller
or change the compression volume of the
deforming workpiece. In addition to the strength
of the wire material, the strength of the frame is a
very important feature in resisting this type of
cracking.
Figure 3. Longitudinal cracks
54.8
26.3
16.9
1.7
0.3
Cracks - 54.8%
Decays - 26.3%
Defects - 16.9%
Scratches - 1.7%
Fractures - 0.3%
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International Journal of Advance Scientific Research
(ISSN
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VOLUME
03
ISSUE
10
Pages:
260-269
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
The boundaries of longitudinal cracks (Fig. 3) are
often jagged and have small cracks along their
edges. The reasons for the occurrence of
longitudinal cracks are as follows:
1.
formation of excessive stretching force;
2.
deviation of the processed workpiece
parameters from the requirements;
3.
failure to meet the operating voltage
requirements;
4.
non-compliance of cooling-lubricating
fluids with specified requirements;
5.
non-compliance of the actual size
diameter of the rollers with the requirements;
6.
the presence of defects in the
microstructure of the hard alloy;
7.
non-compliance
of
the
structural
dimensions of the die channel with the
requirements.
Figure 4. Transverse cracks
Transverse cracks (Fig. 4) are caused by tensile
stresses. Due to cracks on the inner surface of the
roller, changes in stress values begin, which leads
to the erosion of the conical part of the roller.
Because such cracks appear on the surface of the
inner cone, it is difficult to detect them in the
initial stages. If such cracks are not prevented, it
can lead to complete failure of the roller. The
reasons for the occurrence of transverse cracks
are as follows:
1.
the service life of the rollers is broken;
2.
the presence of a defect in the
microstructure of a solid alloy;
3.
when there is a defect in the wire (size,
when disconnected wires are welded together,
etc.).
Volume 03 Issue 10-2023
265
International Journal of Advance Scientific Research
(ISSN
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2750-1396)
VOLUME
03
ISSUE
10
Pages:
260-269
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
Figure 5. Eating in a circle
Circumferential wear of the roller part (Fig. 5).
Usually, corrosion around the working part of the
roller is formed in the roller in the early stages of
its operation. The reason for the appearance of
corrosion is explained by the fact that the voltages
that arise when the wire passes through the
entrance of the wire are increased to a very high
level. Circumferential wear is present in almost
every worn die. Its appearance is explained by the
presence of a soft cobalt phase and excessive
stresses caused by the size and vibrations of the
wire entering the coil.
With the appearance of circumferential wear,
irregularities in the form of steps with a larger
angle appear at the beginning of the contact
surface, and the "ring of wear" formed around the
circumference causes the penetration of cooling-
lubricating fluids into the friction surface
prevents.
The reasons for its appearance are as follows:
1.
parameters of cooling-lubricating fluids do
not meet the requirements;
2.
uneven distribution of cobalt content in
the solid alloy;
3.
geometric dimensions of the working part
of the wire mesh do not match the requirements.
Figure 6. Unilateral defect
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VOLUME
03
ISSUE
10
Pages:
260-269
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
A one-sided surface defect looks like a smooth
surface and has a "non-uniform" shape in the
cross-section of the central hole and the working
cone (Fig. 6). The exact symmetry of the
workpiece is lost or broken. This corrosion is
determined by the chemical interaction between
the wire material and the wire material. Also,
since this is a chemical process, additives or
elements in the cooling-lubricating fluids can also
have an effect. The wear on the rollers looks like
a smooth but slightly uneven surface.
Solid carbide tungsten alloys are rarely
chemically affected. However, the cobalt binder
contained in it can be corroded by chemicals in
coolants such as chlorine, fluorine, sulfur and
nitrates. The reasons for this eating are as
follows:
1.
uneven distribution of cobalt content in
the solid alloy;
2.
symmetrical installation in the case;
3.
symmetrical installation of the roller in the
tool holder of the stretching machine.
Deep scratch of hard alloy part. Deep scratches
extending in the direction of stretching of the wire
spread along the entire length of the working area
of the wire. Corrosion centres appear mainly in
the middle of the working cone and are
accompanied by scratching and tearing of the
hard alloy (Fig. 6). The causes of deep scratches
are as follows;
1.
the presence of solid particles in cooling-
lubricating fluids;
2.
the presence of defects on the surface of
the wire.
a
b
Figure 6. Scratching. A)
–
the internal shape of the die; b)
–
view of the surface from the exit side
Obtaining solid alloys by the powder metallurgy method consists of the following sequential operations:
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VOLUME
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Pages:
260-269
SJIF
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FACTOR
(2021:
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)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
production of tungsten and cobalt carbide
powder oxides by reduction method; grinding
and mixing tungsten and cobalt carbide powders
in grinding machines to particles from 1 to 2
microns;
if necessary, pass through a sieve and
grind further;
preparation of powder mixture according
to the prepared alloy;
adding glue and pressing to special stamp
moulds corresponding to the shape and size of the
product in hydraulic or mechanical presses;
drying compressed products at a
temperature from 80
℃
to 130
℃
;
heating the workpieces in a hydrogen
atmosphere at 1400-1500
℃
. In this, cobalt melts
and wets carbide powders, and when cooled,
cobalt crystallizes and unites carbide particles.
Glue burns at 800-850
℃
.
Carbide cuttings, if necessary, are
processed with a diamond tool.
To increase the eating properties, some
types of products are covered with a coating that
is resistant to eating [3].
Cobalt and tungsten carbide powders are used as
the material of die workpieces for stretching
tools. Table 1 below lists the brands and
compositional properties of the main hard alloys
used for the manufacture of rolls.
An important advantage of single-carbide wires
over wires made of other materials is their high
corrosion resistance, which makes them suitable
for use in large wire drawing environments [4].
Table 1. Brands and structural characteristics of single-carbide hard alloy wheels
Brand
WC, %
Co, %
sB, N/mm
2
not less
g, g/cm
3
HRC
not less
BK3
97
3
980
14.9-15.3
89
BK6
94
6
1180
14.6-15.0
88
BK8
92
8
1270
14.35
87.5
BK10
90
10
1380
14.25
87
R
ESULTS
Analyzing the brands and compositional properties of single-carbide hard alloy wheels means that with
increasing tungsten content, we can see that the hardness of the material increases, but the strength limit
of the material decreases.
Blending
Drying
Grinding
Pressing
Heat up
Heat treatment
Abrasive cleaning
Diamond
processing
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VOLUME
03
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Pages:
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SJIF
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(2021:
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)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
Table 2.
No
Sample mass
Eating
m
0
m
1
m
2
m
4
Δm
1
Δm
2
Δm
3
1
3,298
3,293
3,288
3,275
0.005
0.01
0.023
2
3,298
3,075
3,065
3,053
0.006
0.016
0.028
3
2,458
2,451
2,449
2,447
0.007
0.009
0.011
4
1,956
1,953
1,947
1,943
0.003
0.009
0.013
5
2,807
2,803
2,801
2,798
0.004
0.006
0.009
6
3,935
3,924
3,917
3,914
0.011
0.021
0.006
C
ONCLUSIONS
Experiments on increasing the wear resistance of
hard alloy rolls show that a 2-fold increase in
hardness results in a 1.5 - 2-fold reduction in the
wear of the working tool during the stretching
process. According to the results of this analysis,
the diameter of the wire hole increases more
resistance to a wire stretching without significant
changes; creates an opportunity to increase the
speed of stretching; increase the compression
ratio; ensure the geometric dimensions of the
stretched wire; achieve long-term operation of
the roller without re-control during continuous
stretching; it is possible to save the time spent on
changing the stretching tool and increase the
productivity of the stretching process by taking
into account other factors.
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