STUDY CASE- TAMPING TOOLS WITH THE REINFORCEMENT BY TUNGSTEN CARBIDE AT THE TINE C. Besleaga**, I.C. Popescu*, R.M.

Negriu**, S.G. Badea** *Polytechnic University of Bucharest, Splaiul Independentei nr.313, 77206, sect.6, Romania **Econet Prod, Pades nr. 16, Bucharest, Romania Abstract: An important operation in the technical process of building or maintenance of the railways is tamping. Tamping operation is made by different tamping machine, using tamping tools. Tamping tools are the most stress part of the tamping machine, being stress like bending, oscillations, abrasive wear, a.s.o. The main part of a tamping tool, which influences in present the lastingness of this, is the active part (tine). We propose a study cases with CAD, a new composite material, with tungsten carbide, for the tine and we made the researches regarding to the behavior in situ for the different tamping tools. Keywords: tamping tools, composite material, tungsten carbide, CAD, weariness 1. Introduction The researches regarding to increasing of tamping tools have been made on the three main directions: Theoretical researches regarding to situations stress of a tamping tool, having in view the system stress (forces) and the CAD analyzing; Theoretical and experimental researches regarding to establishing of some new material composition for tamping tine and also, of technological processes by made of this; Experimental researches (in situ), regarding to the behavior of different tamping tools. 2. Study case- tamping tool type BNRI- 85 models 94 For to theoretical study case of the tamping tool BNRI- 85, model 94 (Fig.1), was used two CAD soft (Autodesk Inventor Professional 2008 and ANSYS Workbench, rev. 11), in collaboration with the Thermal Research Center, in the Faculty of Mechanical Engineering and Mechatronics of the Polytechnic University in Bucharest [1, 2]. There are used more then 200000 elements and 3% convergence.

Fig. 1: The Model of tamping tool BNRI 85 types, model 94 For this model were made 6 cases of stress, two from them are presented below. 2.1. Case 3- Checking/ behavior of the tamping tool BNRI- 85, model 94, at case 3 of stress Concentrated force, perpendicular to the lower side (active edge) of the tine, operating in the center of the area (Fig.2 Fig.7).

Fig.2: Scheme of loading

Fig.3: Equivalent stresses (tensions)

Fig.4: Stress (tension) intensity

Fig.5: Life (number of runs)

Fig.6: Total Deformation

Fig.7: Defects (damages)

2.2. Case 5- Checking/ behavior of the tamping tool BNRI- 85, model 94, at case 5 of stress Concentrated force, perpendicular to the active main side of the tine, operating in the center of the area (Fig. 8 Fig.13).

Fig. 8: Scheme of loading

Fig.9: Equivalent stresses (tensions)

Fig.10: Stress (tension) intensity

Fig.11: Life (number of runs)

Fig.12: Total Deformation

Fig.13: Defects (damages)

3. New composite material with metallic carbides For the main piece of wear (tine), we have proposed and achieved a new technological process of casting at the check parameters of a steel, with an original composition, having the role of joint material of the waste from metallic carbide (the waste from metallic carbides are coming from the damage cutting tools, for metal, wood a.s.o.). The original composite material which has been achieved is made from particles of metallic carbides, with a certain granulometry (size), incorporation through diffusion into metallic matrix. The matrix of the composite material is heating over the melting point of the binding material from waste composition of sintered metallic carbides (WC-Co, WC-Ni, WC-Co-Ni and TiC-X) and it is casting into relative cold form (shape). The binding metal (Co-Ni) is dissolved and diffusion into metallic matrix and after that it is solidifies. We have achieved a composite material, which is able to satisfied the hard wear conditions, at the local abrasive wear stress, vibrations, having a hardness bigger than the limit conditions impose by the crushed stone abrasiveness [3, 4, 5, 6, 7].

Fig.14. Micro dilution of carbides particles Carbides - Detail x 12000 The main types of analyzed particles are titan carbides (TiC) and tungsten carbides (WC). The infiltrations analyze with particles from metallic carbides has showed the fact that the TiC has a finest particles shape, with relative round shape, which confer a good plasticity of the reinforced matrix, while the WC has a rough morphology, with sharp edge and corner, conferring resistance and hardness. The combination of both effects has a good results, by point of view of the behavior in function, if are resolved the problems regarding to the fragility and fissure tendency of the composite metallic material. The phenomenon which occur at the interface between metallic matrix and carbide particle are depending in a big measure by the size, chemistry and physics characteristics of these, and also, by the manufacturing. 4. Experimental procedure We have established an experimental procedure [8], for evaluated the lastingness of a tamping tool. The lastingness of a tamping tool is the period of time, in which the tamping tool work in the established parameters (until to reaching the limits of wear of an active partthe tine), until to a new regeneration (Fig. 15). The lastingness of a tamping tool can be evaluated through meters (kilometers) of tamping, hours of tamping or, number of insertion. Because the evaluation of lastingness in meters (kilometers) can be use more easily, we have adopted this unit. For the limits of the wear of tine, having in view indications [8] and our experience, we have adopted the following size of wear: 15 mm on side; 20 mm at the corner (40 mm on diagonals).

Fig.15. The limits of the wear for active part (tine) of a tamping tool

Ui = h hi; i= 1 6; Umed = (U1+ U2+....+ U6): 6 5. Researches in situ on the different lots of the tamping tools After the researches, regarding to established which is the main tamping tool (having in view the quantity, consumption criteria) which is use in present, from all types of tamping tools which are used, the researches in situ have been concentrated on the tamping tool BNRI- 85, model 94, followed that the conclusions of these researches to be extended to all types of the tamping tools. 5.1. Experimental researches in situ on the lot 1 of the tamping tools The experimental researches (in situ) have been made with BNRI- 85 tamping machines, on three tamping tools type BNRI-85, model 94, identified with G4, G6 and G8(7), with the tine which have been made on the base of a new composite material, with tungsten carbide (Fig.16, 17, 18). The behavior of these tools, taking in account the weariness [mm] depending by [km] of tamping is present in Fig. 19.

Fig.16. Tamping tool G4 Fig.17. Tamping tool G6 Fig.18. Tamping tool G8 (7) 5.2. Experimental researches in situ on the lot 2 of the tamping tools For comparison, we have established another lot, number 2, with 8 tamping tools type BNRI-85, model 94, which have been made by another producer, having as main material for the body of tamping tool and the active part (tine) of this, the alloy steel 42MoC11. The active part (tine) of a tamping tools, in areas which are the most stress at wear (abrasive wear a.s.o.), have been protected through welding with a hard material like EI 58 H electrode. The lot 2 (with 8 pieces) it have been identified with B21 B 28. The behavior of these tools, taking in account the weariness [mm] depending by [km] of tamping is present in Fig. 19. 5.3. Experimental researches in situ on the lot 3 of the tamping tools The eight tamping tools type BNRI-85, model 94, which were presented above, after it work until to the admissible limits (see chapter 4), it has been reconditioning at the active part (tine) through welding, with two materials: 4 pieces with EI 58 H electrode, which have been identified with B21 (R1) B 24(R1) and 4 pieces with EI 16 Mn electrode, which have been identified with B25 (R1) B 28(R1). The behavior of these tools, taking in account the weariness [mm] depending by [km] of tamping is present in Fig. 19.
[mm] 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39

Ciocane BNRI - 85

G4 G6 G8(7) B21 B22 B23 B24 B25 B26 B27 B28 B21(R1) B22(R1) B23(R1) B24(R1) B25(R1) B26(R1) B27(R1) B28(R1)

[km]

Fig.19. The wear curves of the active part (tine) for experimental tamping tools

Conclusions: - Designing a tamping tool and checking of this, to the different stress, with especially CAD simulation, can offer many advantages, possibilities and reduce a lot of time and more accurate results. - The new composite material with tungsten carbide, on which we have proposed, has a good potential and goods properties for wear, being chip and use the waste from different damage parts from tungsten carbide. - In comparison, the average of weariness of tamping tools, after 9 km, with new composite material (with tungsten carbide) for the tine (lot 1: G4, G6, G8 (7)) is with 4,5 times smaller than the average of weariness of new tamping tools (lot 2: B21 B28) and with 6,5 times smaller than the average of weariness of reconditioning tamping tools (lot 3: B21 (R1) B28 (R1)). In the end, the average of lastingness for lot 1 (G4, G6, G8 (7)) is with 2,8 times bigger than average of lastingness for lot 2 (B21 B28) and lot 3 ((B21 (R1) B28 (R1)). This fact, make the possibility to reduce the cost of a tamping tool, a tamping operation and maintenance of railways. References: [1] I.C. Popescu, Introduction in computer aided analysis of the process equipments , Printech Publisher, ISBN 973- 652- 951- 7, Bucharest, (2004) [2] I.C. Popescu, T. Prisecaru, B. Finite elements Analysis of Pressure Equipment, Computer Aided Engineering Solutions for Design, Analysis and Innovation, (ANSYS & FLUENT User Group Meeting), 26-27 Aprilie 2007, Sinaia [3] P. Georgeoni, N. Arnici, I.C. Popescu, and s.a., Using the isostatical pressing at the manufacturing of big machine parts by high performances from sintered metallic carbides, Metallurgical Researches, ICEM, Vol.26, page. 463 - 475, 1985, Bucharest. [4] P. Georgeoni, I.C. Popescu, Considerations regarding to manufacturing of machine parts from metallic carbides type WC-Co with A.I.P. destination , Metallurgical Researches, ICEM, Vol.26, page. 477 - 483, 1985, Bucharest. [5] V.V.Jinescu, I.C. Popescu, Reactors by very high pressure with the elements manufactured from the tungsten carbides and cobalt , Chemistry Review, nr. 12, 1997, page. 981 - 991, ISSN 0034-7752, (ISI-MJL 7569); [6] V.V.Jinescu, I.C. Popescu, Reactors by very high pressure with the elements manufactured from the tungsten carbides and cobalt , II, Chemistry Review, nr. 1, 1998, page. 56 - 63, ISSN 0034-7752, (ISI-MJL 7569); [7] P. Georgeoni, I.C. Popescu, M. Istrtescu, L. Argeanu, The behavior of different types hardness alloys from WC Co system, used at manufacturing of dies for reactors by very high pressure, Mechanical Breakage, nr. 9, page. 8 - 14, 2000, ISSN 1453-8148; [8] Cr. Besleaga, Contributions regarding to increase the lastingness of the tamping tools, Doctorate thesis, 625.144.5(043-2876) B-UP 1, Bucharest, (2006).