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H e t a i l o v e d e n i e i Term, Obrabotka HetaIlov, Nov. 1959, #11, p.

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From

HB No. 5161.

UNUSED [INADEQUATE

PRODUCTION OF

RESERVES

FILLING

C A R B U R I Z I N G BOXES]

B. I. S h a s h k i n

It is c o m m o n l y a s s u m e d t h a t u n d e r n o r m a l p r o c e s s c o n d i t i o n s , the w e i g h t of the c a r b u r i z i n g c o m p o u n d i n t h e b o x s h o u l d be 10% to 15% of the w e i g h t of t h e p a r t s t r e a t e d . A c a l c u l a t i o n s h o w s t h a t i n v i e w of t h e l a r g e d i f f e r e n c e s i n t h e s p e c i f i c d e n s i t i e s of t h e l o o s e c o m p o u n d ( 0 . 4 5 ) a n d the s t e e l ( 7 . 8 4 ) , t h e f o r m e r o c c u p i e s 2 / 3 - 3 / 4 of the b o x v o l u m e . H e n c e , to o b t a i n a n o r m a l l a y e r , t h e p a r t s s h o u l d o c c u p y 25% to 35% of the t o t a l b o x v o l u m e . T h e o r e t i c a l c a l c u l a t i o n s of t h e n e c e s s a r y a m o u n t of c a r b u r i z e r i n t h e b o x a r e n o t a v a i l a b l e . T h e v a r i o u s f o r m s of the c a r b u r i z e d p a r t s , t h e d e s i g n d e t a i l s of f u r n a c e s , d i f f e r e n c e s i n t e m p e r a t a r e c o n d i t i o n s of t h e p r o c e s s a n d d i f f e r e n t c a r b u r l z e r p r o p e r t i e s m a k e s u c h c a l culations impossible. H o w e v e r , t h e a b o v e i n d i c a t e d w e i g h t r a t i o s of c a r b u r i z e r (10% - 15%) to p a r t s a r r i v e d at i n m a n y y e a r s of p r a c t i c e , s e c u r e a s u f f i c i e n t l y h i g h q u a l i t y of the treatment. A c e r t a i n l o a d i n g o r d e r of p a r t s i n t o t h e c a r b u r i z l n g b o x w a s e s t a b l i s h e d . In a l l t e x t b o o k s a n d i n s t r u c t i o n s c o v e r i n g c a r b u r i z i n g , a s p e c i f i c s p a c ing b e t w e e n the p a r t s t h e m s e l v e s or b e t w e e n the p a r t s and the wails and b o t t o m of t h e b o x a r e r e c o m m e n d e d w i t h o u t g i v i n g a n y r e a s o n s . F o r n o r e a s o n , it i s a l so a s s u m e d t h a t c o n t a c t a m o n g t h e p a r t s w i l l r e s u l t i n a b s e n c e of a c a r b u r i z e d c a s e at the c o n t a c t p o i n t s . We h a v e s h o w n i n o u r a r t i c l e s t h a t t h i s a s s u m p t i o n i s c o m p l e t e l y e r r o n e o u s ( " M e t a l l o v e d e n i e i O b r a b o t k a M e t a l l o v " , 1955, No. 6, pp 4 0 - 4 4 ; " l t a t s i o n a l i z a t o r y P r o m y s h l e n n o s t i " , T e k h l z d a t , O b l i g i z 1957). A l l t e c h n i c a l i n s t r u ' c t i o n s u s e d b y t h e p l a n t s r e q u i r e a d h e r e n c e to t h e r u l e s of p a c k i n g w i t h s p a c e s i n b e t w e e n , t h i s l e a d i n g to a u n j u s t i f i a b l e a n d u n a c c e p t a b l e l o w e r i n g of p r o d u c t i o n r a t e s i n a n a l r e a d y v e r y l o n g a n d t i m e - c o n s u m i n g p r o c e s s . A s a n e x a m p l e of a d e v i a t i o n f r o m the n o r m a l l o a d i n g p r a c t i c e , we w i l t r e f e r to t h e o p e r a t i o n of s e v e r a l S a r a t o v p l a n t s . T h e b a l l b e a r i n g p l a n t u s e s c a r b u r i z i n g b o x e s of s i z e s I. 25 0 . 4 X 0 . 4 5 m a n d 0 . 9 5 X 0 . 4 5 0 . 5 m ; t h e y a r e f i l l e d w i t h p a r t s of f o u r t y p e s w h i c h o c c u p y i n t h e a b o v e b o x e s 11, 15, 18, i 9 a n d 2 0 ~ of the t o t a l v o l u m e , r e s p e c t i v e l y . A m e c h a n i c a l w o r k s u s e s b o x e s of two t y p e s , a n d the p a r t s o c c u p y i n t h e m 8 . 2 5 % ; 10. 1%; 1 0 . 5 % ; 1 2 . 1 % ; a n d 1 7 . 2 % b y v o l u m e . At a p l a n t for oilwell e q u i p m e n t , t h e c a r b u r i z i n g b o x e s a r e 0 . 3 X 0 . 3 X 0 . 6 m ; t h e p a r t s o c c u p y 25% a n d 17. 1% b y v o l u m e . A t t h e " H a m m e r a n d S i c k l e " p l a n t , i n a b o x w i t h i n s i d e d i m e n s i o n s 0. 924 )< 0. 35 0. 480 m , 60 p a r t s e a c h w e i g h i n g 3 . 2 k g a r e l o a d e d , t h i s r e p r e s e n t i n g 16% of t o t a l v o l u m e . I n o n e p l a n t t h i r t e e n t y p e s of t a p p i n s a r e c a r b u r l z e d , t h e v o l u m e u s a g e b e ing 7 . 5 % - 11.8%. I n m a n y o t h e r p l a n t s t h e r a t i o b e t w e e n t h e v o l u m e of t h e s t o c k t r e a t e d a n d t h e t o t a l v o l u m e of t h e c a r b u r t z i n g b o x e s i s a p p r o x i m a t e l y t h e s a m e . C h a r g e s of c a r b u r l z i n g b o x e s c a n b e s u b s t a n t i a l l y i n c r e a s e d w i t h o u t a f f e c t i n g t h e q u a l i t y of t h e c a r b u r i z e d l a y e r . I n m a n y c a s e s , t h i s i n c r e a s e w i l l d o u b l e o r e v e n t r i p l e the o u t p u t w i t h o u t a d d i t i o n a l c o s t s . We h a v e i n d i c a t e d a b o v e t h a t p a r t s s h o u l d o c c u p y b e t w e e n 25% a n d 33% 35% of the t o t a l v o l u m e of t h e b o x . I s t h i s p o s s i b l e ? Y e s , it i s , a s s h o w n n o t only by calculation but by experience aa well. 49

In a plant building gear shapers, the packing of the parts of a single type is determined ~ast by this m a x i m u m figure, i.e. 3 B ~ of the total box volume. It is unfortunate that a charge of slide blocks takes up only 2 5 ~ of the total volume of the carburizlng box whereas that of still other parts, only 17~0. Occasionally the shape of the parts precludes m a x i m u m use of the box volume {hollow elements, plates, etc.I. In such cases, a lower ratio of parts volume to total volume would be permissible, but they are relatively rare. S o m e production m e n are afraid of high filling percentages, assuming that in such case the quantity of carburizer will prove insufficient. This fear is completely unjustified. W e will quote s o m e figures~: with a m a x i m u m filling degree of 33~, the carburizing c o m p o u n d represents Ii~ of the weight of the parts. With such a ratio, the above mentioned gear shaper works obtains good quality casehardening. W h e n the volume used is ZS~, the weight of the carburizer is I?~ of the metal weight, i.e. above the upper r e c o m m e n d e d limit. Lighter charges involve a completely unjustifiable waste of carburizer. Thus for 16~0 filling, the weight of the carburizer is B0~, i.e. twice, at I i~, three times, and at 7.5~, four times the r e c o m m e n d e d m a x i m u m . These convincing figures actually underrate the situation, because the above-indicated 0.45 factor is based on unpacked density of the carburlzer. In operation, the carburizer is tamped, broken up, compacted, s o m e dust is f o r m e d and w e should have taken in our calculation a factor of not 0.45, hut perhaps 0.6 0. ?. The settling dust and salts coat the parts, thus slowing d o w n the process. T h e author considers that plants should be advised to take better advantage of the useful volume of carburizing boxes.

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