DETERMINATION OF THE DEFORMATIONS OF THE GUIDES

OF A MILLING MACHINE BASE OCCURRING DURING FRICTION HARDENING

V. G. Abashkin, V. I. Buchma, UDC 620.178.6

V. M. Gurei, Z. G. Dutsyak,
and M. A. Shafarevich

To increase the wear resistance of the guides of metal cutting machine base parts, there
are various methods of hardening [1-3] which because of a number of disadvantages have not
found wide use. The most widely used is high-frequency induction surface hardening [4, 5]
but it causes warping of the guides and the base.
At present a method of friction hardening of parts has been developed [6]. The essence
of the method includes the formation in a thin surface layer of hard wear-resistant struc-
tures. Such structures occur in friction of a steel disk on the surface being hardened.
It remains unclear what influence friction hardening has on deformation of the guides
and the base as a whole. This article is devoted to a study of this question.
The determination of deformations in the base during friction hardening and, for com-
parison, during grinding was made under plant conditions.
The guides of the base of a Model 6520-FZ horizontal milling machine of Lvov Milling
Machine Plant, made of CCh21-40 iron (GOST 1412-70) which had been artificially aged, were
hardened. The hardening was done on a Model 3510 transverse grinder. The tool was a disk
of hardened and low-temperature tempered 40Kh steel (HRC 48) with a diameter of 400 nm and
a width of 25 mm placed on the rotating head of the machine and rotating at a speed of 60
m/sec. The working surface finish of the disk was Class 8-9. The friction hardening was
done with a transverse feed of 2.5 mm/double stroke, a vertical feed of 0.I mm, a rate of
movement of the table of 4 m/min, and an abundant supply of oil in the zone of hardening.
The deformation and temperature were measured both during hardening and after it (in a
condition of rest) with the use of type 2PKB 20-200 wire gauges and appropriate equipment,
making it possible to determine the statics and dynamics of the process. The static deforma-
tions were recorded with a strain gauge bridge recording the stresses with an error of 0.5
MPa and the dynamics of hardening were recorded with a TA-5 amplifier and a K-12-22 Oscillo-
graph. Forty gauges (Fig. i) were cemented to the part for the purpose of revealing the
deformations occurring as a result of warping of the base, which may be propagated by a half-
wave or a wave in the horizontal and vertical planes. The deformations during hardening
were measured in four positions of the hardening disk across the width of the guide, at
entry of the diskp at a distance of 20 mm from the edge of the guide, in the center of the
guide, and at exit of the disk. The static stresses were recorded directly after hardening
or grinding and also 0.5 h after.

f 5 2221 ~01~18IS171813181~0 ~ 2~ s ~ 1 2 5 1211

5G
57
3g
3*
3~

Fig. i. Plan of placement of the sensors.

Lvov Wood Technology Institute. Translated from Fiziko-Khimicheskaya Mekhanika Mate-

rialov, Vol. 17, No. 3, pp. 96-98, May-June, 1981. Original article submitted January 21,
1980.

290 0038-5565/81/1703-0290507.50 9 1982 Plenum Publishing Corporation

 2f

- S Id20 i . i 9

400 800 ,1200

21 " '20 ~
Length of the base, rnm
Fig. 2 Fig. 3
Fig. 2. The static stress distribution along the length of
the base in hardening. The numbers are the number of the
gauges.
Fig. 3. Oscillogram of deformations of the base guide.
Numbers are the numbers of the gauges.

40 6 " 4

-f

-8
0 20 40 . 80 80
Width of guide,m m
Fig. 4. The change in stresses
across the width of the guide (I --
gauge 20, 2 -- gauge 21, 3 -- gauge
22) and in the average temperature
(4) in relation to the position of
the hardening disk.

The stresses found by static strain measurement both after grinding and after hardening
were almost equal and primarily within limits of 2-5 MPa. The remaining points reached
maximum values of 7 MPa for grinding and 6 MPa for hardening. The character of stress dis-
tribution in hardening and grinding was identical (Fig. 2). On the face of both guides
(gauges 1 and 20) compressive stresses occur, which lead to tensile stresses in the center.
In the base of the guides the stresses are close to z e r o . The measurement of the stresses
made 0.5 h after grinding and hardening did not reveal substantial changes.
The investigation of dynamic stresses during hardening was made with the use of the
gauges recording the maximum values in static strain measurement (20, 21, and 22). The
deformation distribution during hardening was recorded for four positions across the width
of each guide (Fig. 3). On the oscillograms peaks may be seen which correspond to passage
of the hardening disk above the gauges. The fact that some peaks are higher than others
is an indication of the different degrees of deformation in forward and reverse hardening.
The stresses in reverse hardening are more significant.
On the basis of oscillograms for the different positions of the hardening disk across
the width of the guides curves were drawn which provide a visual representation of the
change in stresses during hardening (Fig. 4). The measurement results provide the follow-
ing approximate picture. When the disk has just started hardening, touching the surface
of the guides, the stresses are low. Then, with movement of it across the guides the
stresses increase, reaching the maximum (6.3-8.2 MPa) in the center of the guide. At the
exit of the disk the stresses again drop. At the completion of hardening the stresses
(residual) at the points of placement of the gauges vary within limits of 1.6-6.6 MPa.

291
 The surface temperature of the guides occurring during hardening plays a substantial
role in the sense of providing the possibility of phase transformations of the iron capable
of causing high stresses and leading to warping of the base. To measure the temperature
resistance, sensors were cemented on in such a manner that their network was located at a
distance of 6 mm from the edge of hardened surface of the guide. The temperature curves
recorded by the sensors during hardening by an oscillograph are similar to the stress dis-
tribution curves. In hardening of the guide the metal is heated to 61~ despite the fact
that in the hardening zone the impulse temperature reaches 1000~ [6]. However, such a
high impulse temperature drops rapidly as a result of flow of heat from the comparatively
thin surface layers into the depth of the metal and losses into the surrounding medium and
also into the hardening disk. Warping of the base may occur from internal stresses created
by hardening.
The allowable error, according to plant specifications, is 0.015 mm on a surface. Ac-
cording to calculation, the stresses capable of causing warping of the base are 10-13 MPa.
Those recorded by us at the completion of hardening are half as much.
Therefore, the residual stresses in hardening do not exceed 6.6 MPa, which corresponds
to the level of stresses occurring in grinding. The stresses from friction hardening and
the residual stresses as a result of working are in that optimum range in which warping of
the base is eliminated.

LITERATURE CITED"
. L. A. Sobolev, "Increasing the life of metal cutting machine guides by metallizing of
them," Stanki Instrum., No. 3, 43-44 (1967).
2. K. P. Dolgov and E. G. Nizhnik, "The design and repair of cemented guides," Stanki
Instrum., No. 3, 18-20 (1967).
3. M. O. Yakobson, "The surface quality and life of straight-line metal cutting machines,"
in: The Surface Quality of Machine Parts [in Russian], No. 5, Izd. Akad. Nauk SSSR,
Moscow (1961), pp. 348-355.
m V. P. Mitrovich, A. E. Bondarevskaya, and L. R. Avanesov, "The wear of machine base
parts of hardened iron," Stanki Instrum., No. 7, 29-31 (1970).
5. O. Yu. Kotsyubinskii and G. A. Adoyan, "The warping of iron parts with hardened
guides," Stanki Instrum., No. 7, 20-21 (1972).
6. Yu. I. Babei, "Machining as a method of increasing the life of constructional alloys
in active media," Fiz.-Khim. Mekh. Mater., No. 2, 3-14 (1975).

292