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Analysis of AISI material power of AISI 4140 bucket teeth excavator using influence of abrasive wear
Abstract
Excavators are often used in the mining and construction projects. They are the digger machines normally used for dredging materials in mine, digging, leveling the ground, dredging the river, etc. One of the components of excavator that is frequently replaced is bucket teeth. The replacement of bucket teeth is mainly due to the wear factor occurring in this component. To decrease the wear of the material, heat treatment is applied to increase the material hardness value and eventually, to have high competitiveness in product marketing. Material used in this research was AISI 4140, and the heating process was performed on laboratory’s furnaces. The selected cooling medium was water. Analysis was done to determine the values of wear factor, hardness, and micro structure. The investigation of micro structure was done by using optical microscope, hardness test was done using Rockwell hardness tester, and wear test was performed using Ogoshi High Speed Universal Wear Testing. From the results of the analysis, it can be concluded that hardness value is inversely proportional with wear value, the harder the material, the lower the wear value. Meanwhile, the influence of material hardness is the magnitude of Mn in a bucket tooth.
... There is many equipment used in construction field; however, excavator is one of the most heavier equipment which perform many tasks such as cleaning, miming and digging [1]. Excavator is assembled from different parts; however, the most important part is the buckets of the digger [1,2]. ...
... There is many equipment used in construction field; however, excavator is one of the most heavier equipment which perform many tasks such as cleaning, miming and digging [1]. Excavator is assembled from different parts; however, the most important part is the buckets of the digger [1,2]. Teeth are the main links of buckets that assembled at the front edge. ...
... Considering this role of the teeth, it should have some properties such as good tensile strength, hardness and impact. In addition, the chosen material should have good wear resistance; otherwise, failure of the digging teeth may be occurred periodically [1,3]. Bucket teeth are replaced periodically owing to their small service life caused by fracture and/or wearing [1]. ...
The objective of this paper is to enhance service life of excavator bucket teeth for decreasing the idle time required to reinstate the teeth periodically during excavation process. To achieve this goal, medium-carbon steel was chosen with a chemical composition of 0.41C, 0.23Si, 0.75Mn, 1.0Cr, 0.23Mo (wt.%) to cast as Y-blocks with wall thickness of 30 mm using medium-frequency induction furnace. Optimum tensile strength (1492 MPa) and hardness (474 HV) were obtained for the sample quenched at 220 °C. Optimum impact toughness (17 J) was reported for the samples quenched at 270 °C compared to the as-cast sample (9 J) and quenched one at 220 °C (14 J). The lowest wear rate was shown for the quenched sample at 220 °C compared to the as-cast and quenched sample at 270 °C. The best combination of wear resistance, hardness, impact toughness and tensile properties was achieved for the quenched sample at 220 °C.
... Excavator is a heavy equipment frequently used in the construction and mining activities [1]. Excavator bucket is one of the main components of excavator and it is used for digging and loading [1,2]. ...
... Excavator is a heavy equipment frequently used in the construction and mining activities [1]. Excavator bucket is one of the main components of excavator and it is used for digging and loading [1,2]. Bucket contains protruding teeth on its edge. ...
... In the operation of excavator, teeth have direct contact to ground or rocks. For this reason, the material used for teeth should have high strength, high toughness, high power and high wear resistance [1,3]. Moreover, teeth are renewed sporadically due to their limited service life arising from the ground or rock penetration [1]. ...
The effect of Ti addition (0.15 and 0.20 wt%) on mechanical properties and wear resistance of steel excavator bucket teeth was investigated. Teeth were produced by commercial sand casting technique. After production normalizing, hardening, and tempering heat treatment procedures were applied to the teeth. Lath martensitic microstructure was observed and small amount of carbide particles were present in the microstructures of Ti containing ones. In addition, small amount of hard and brittle TiN particles were observed in the microstructure of 0.20 wt% Ti containing teeth. The best mechanical properties were obtained for 0.15 wt% Ti containing teeth with considerably high abrasive wear resistance. However, 0.20 wt% Ti containing teeth exhibited worst abrasive wear resistance and limited ductility due to the formation of TiN particles.
... Dalam penelitian ini perancangan desain menggunakan pendekatan dari desain asli yang didapat dari pasaran. Untuk properties material yang akan diinput dalam simulasi, penulis merujuk pada penelitian yang dilakukan oleh Arief yang menjelaskan bahwa material bucket tooth yang dia uji adalah AISI 4140 [3]. Dalam simulasi ini digunakan metode linear statik untuk proses optimasi. ...
... Pada penelitian ini, penentuan material bucket tooth yang digunakan merujuk pada penilitian Muhammad Arief yang membahas tentang karakterisasi material pada bucket tooth yang sudah ada di pasaran, yaitu AISI 4140 [3]. Data-data yang diperoleh dari penelitian tersebut diperlukan dalam proses optimasi desain bucket tooth kali ini. ...
... Data tersebut dapat dilihat pada Tabel 1 sebagai berikut. Tabel 1. Data Karakteristik material AISI 4140 [3]. ...
Excavator merupakan alat berat yang biasanya digunakan untuk menggali tanah, membelah batu, membongkar jalan atau merobohkan bangunan. Salah satu komponen yang berperan dalam fungsi tersebut adalah bucket tooth. Pada penelitian ini membahas tentang perancangan optimasi bucket tooth yang ada di pasaran untuk menghasilkan desain yang lebih ringan tetapi tetap mempertahankan kekuatannya, bucket tooth tersebut adalah Verona PC200. Proses optimasi pada bucket tooth menerapkan konsep optimasi topologi. Metode yang dilakukan meliputi penentuan jenis material yang dipakai dengan berbagai pengujian yaitu uji komposisi, uji mikrografi dan uji kekerasan. Kemudian dilakukan analisis linear statik menggunakan metode elemen hingga untuk melihat tegangan maksimum yang terjadi pada bucket tooth, besarnya nilai tegangan Von-mises sebesar 403,81 MPa. Selanjutnya dilakukan optimasi topologi dengan memilih beberapa variasi area desain yang menghasilkan reduksi massa dalam variasi pertama sebesar 0,72 kg dan pada variasi kedua 1,49 kg. Reduksi massa tersebut menyebabkan perubahan tegangan yang terjadi pada bucket tooth menjadi 451,8 MPa pada variasi pertama, dan 458,6 MPa pada variasi kedua, namun tegangan tersebut masih dalam kondisi aman.
... Dalam pengoperasian excavator, gigi memiliki kontak langsung dengan tanah atau batu. Untuk alasan ini, bahan yang digunakan untuk gigi harus memiliki kekuatan dan ketangguhan yang tinggi [1] [2] . Namun, sifat mekanik dan fisik baja ini perlu ditingkatkan dengan penambahan elemen paduan, dikarenakan aspek penting dari penerapan rekayasa [3] . ...
The purpose of this study was to determine how the mechanical properties and microstructure formed on low alloy steel (tooth bucket) heated at temperatures of 850 ⁰C and 850 ⁰C then held for 15 minutes after that it was cooled with oil. The material hardening process was carried out by testing the Vickers hardness, impact, and observing the microstructure using an optical microscope with 200x magnification. Hardness values obtained from low alloy steel after heat treatment at temperatures of 800 ⁰C and 850 ⁰C are 389.2 HV and 414.6 HV. The optimum hardness is obtained at a temperature of 850 ⁰C with an increase of about 1.14% compared to that of raw material, which is 364.5 HV. From the results of the impact test on heat treatment with a temperature of 850 ⁰C, the highest impact value is 0.574 Joule/mm2. Furthermore, the results of the microstructure on heat treatment at a temperature of 850 ⁰C resulted in homogeneous microstructures, namely chrome, martensite, and bainite.
... Bucket teeth and other earth cutting edges are most likely made from a high manganese steel due to their excellent hardness and wear properties. It has been suggested that AISI 4140 can also perform well as a bucket tooth material (Herbirowo, S, Syahrum, M, Hasbi, M Y, Chandra, S A, Ridlo, F M, & Adjiantoro, B, 2019;Suryo, S. Hadi, Bayuseno, A.P., Jamari, J., Ramadhan ,Muhammad Arief Rahmat, 2018). For this project, ASTM A514 will be used to represent the bucket walls and AISI 4140 will be used to represent the teeth. ...
Welding repairs of heavy equipment in the field can vary in levels of success. This can be due to the high strength steels used in the manufacture of heavy equipment implements that require special metallurgical considerations. Repair difficulties can be further compounded by the limitations of tooling typically found on a construction site and schedule commitments. Overloading or excessive impacts can cause damage to the bucket teeth of an excavator or bulldozer rippers. A shop could perform a proper repair but that increases cost and takes precious time. A successful repair of these items done out in the field can reduce downtime and improve productivity. This project will attempt to develop a welding procedure that can be done in the field to successfully repair such damage. Considerations will be given for tooling that can typically be found on the construction site and skills familiar to a contractor or operating engineer. Using the structural steel welding code as a guide, different welding procedures will be compared for their ability to successfully weld high strength steels like that found on heavy equipment. Equipped with this welding recipe, anyone who can weld would be able to make a successful repair.
... Material powders deposited were supplied by Kennametal Pty (Ltd) and consisted of Tribaloy T-800 with particle size distribution of +45-90 μm. Based on literature, most excavator bucket teeth were found to be manufactured from heat treated 300-400 steel series [5][6][7]. Therefore, single track-single layer clads were deposited on a 304L stainless steel substrate and repeated twice. All measurements reported in this study are an average of two readings with standard deviation varying between 0.01 and 0.07%, 0.05 and 0.06% and 0.009 and 0.05% for microhardness, specific wear rate and coefficient of friction, respectively. ...
Taguchi design of experiments (DoE) was employed to determine appropriate laser cladding (LC) parameters for optimising microstructural and anti-wear properties of Tribaloy (T-800) coatings. The nature of wear mechanism was also explored with scanning electron microscopy (SEM). Statistical analysis established that both microhardness and wear rates were primarily dependent on powder feed rates and scanning speeds while coefficient of friction (COF) is significantly influenced by spot diameter. Variation in wear morphology, across the samples, could be explained by presence or absence of surface defects; sizes of surface defects, distance between the surface defects as well as the nature of evolving microstructure within the clad samples. Optimum samples were imparted with microhardness (900 HV), COF (0.0743) and specific wear rate (0.0071 mm³/N/m), and these compared favourably well with the predicted values. Samples fabricated with optimum LC parameters are suitable for wear application in mining industries.
Low-alloy wear-resistant (LAWR) steels are one widely used materials for bucket teeth in excavator. We employ the density-functional theory to investigate the solute atoms effect on the elastic properties of body-centered cubic Fe and the main alloying phases of LAWR steels. First we determine the equilibrium lattice parameter and single-crystal elastic constants and compare them with previous theoretical/experimental results. The intrinsic ductility is evaluated from Pugh’s theory obtained from the ratio between bulk modulus and shear modulus and Poisson’s ratio. Combined with the empirical equations, the alloying effect on the Vickers hardness and the energy factors of screw and edge dislocations are considered. Alloying with Mn is found to enhance the hardness and the energy factor of screw dislocation.
This work was devoted to preparing a kind of the ultrastrong low alloy wear‐resistant steel suitable for excavator bucket teeth. The ultrastrong steel with good toughness and wear resistance has been successfully prepared by the forging, quenching and tempering process. The yield strength, tensile strength, elongation and hardness of the ultrastrong steel reached up to 1700 MPa, 1960 MPa, 7% and 563HV, respectively. OM, SEM and TEM were used to observe the microstructures of the ultrastrong steel. After the forging, quenching and tempering, two types of martensite laths were formed in the matrix of the ultrastrong steel, i.e., the coarse laths with low‐density dislocations and the thin laths with high‐density dislocations and some ε‐carbides. Low‐temperature tempering allows the carbides to precipitate in large quantities, and maintains the matrix with high density dislocations in the thin laths, which is the micromechanism of the steel with high strength and high toughness, good wear resistance.
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The importance of various form of heat treatment operations on medium carbon steel in order to forester the problem that may arise in making a wrong choice of these steel materials or faulty heat treatment operations which may give rise to serious disruption in terms of human safety, higher cost and untimely failure of the machine components is of great concern. The mechanical properties such as ductility, toughness, strength, hardness and tensile strength can easily be modified by heat treating the medium carbon steel to suit a particular design purpose. Tensile specimens were produced from medium carbon steel and were subjected to various forms of heat treatment processes like annealing, normalizing, hardening and tempering. The stiffness, ductility, ultimate tensile strength, yield strength and hardness of the heat treated samples were observed from their stress-strain curve. The value of the yield strength (σ y) was observed to be higher for the tempered specimen possibly as a result of the grain re-arrangement, followed by the hardened, normalized and annealed specimens. The value of the ultimate tensile strength (σ u) were also observed to be in the order; hardened> tempered>normalized>annealed.
Investigations were carried out to study the effects of heat treatment on the mechanical
properties of rolled medium carbon steel. The steel was heated to the austenizing temperature of
8300C and water quenched; It was reheated to the ferrite – austenite two phase region at a
temperature of 7450C below the effective Ac3 point. The steel was then rapidly quenched in
water and tempered at 4800C to provide an alloy containing strong, tough, lath martensite
(fibres) in a ductile soft ferrite matrix. The result shows that the steel developed has excellent
combination of tensile strength, impact strength and ductility which is very attractive for
structural use.
Keywords: Lath martensite, Ferrite, Austenite, Tensile strength and Ductility.
Several spheroidizing processes were carried out on the ultrahigh carbon steel, and the microstructures and mechanical properties of the samples under different heat treatment were observed and tested. The effect of heat treatment on microstructure and mechanical properties of the ultrahigh carbon steel was discussed. The results show that the toughness of the steel is improved remarkably with the increase of the spheroidizing ratio of carbides. The sample quenched at 840°C for 20 min and tempered at 650°C for 3 h possesses of high strength (σs=576 MPa, σb=835 MPa) and good plasticity (δ5=18.4% ) because of obtaining more round carbides. Also the sample normalized at 1200°C for 4 h and spheroidizing annealed at 800°C, for 2h has higher strength (σs=622 MPa, σb =927 MPa) with slightly low plasticity (δ5=16.0% ) because of the uniform distribution of fine spherodized carbides in it . Although there is a certain lamellar carbides in the samples annealed at 720°C for 3.5 h, as well as annealed at 840°C for 10 min and then at 720°C for 2.5 h, they have higher strength (σs≥590 MPa, σb≥870) and relatively low plasticity (δ5≥11%).
This paper demonstrates the effect of heat treatment and extrusion ratio on microstructure and mechanical properties of AM50 Mg alloys. The results show that extrusion deformation can fine the grain of Mg alloy and increase its mechanical properties remarkably. After solution heat treatment, the net-like β-Mg17Al12 phase almost dissolved in Mg matrix. Preferable mechanical properties can be obtained because of second phase precipitation caused by deformation during extrusion processes.
The effect of heat-treatment on mechanical properties and microstructure of TCS stainless steel by box-type resistance furnace was investigated. It is found that the heating temperature and the holding time have little effect on mechanical properties of steel when the heating temperature is below 900°C. While the heating temperature is above 900°C, the tensile strength and hardness are first quickly increased and then slightly decreased with increasing the heating temperature. The maximum values of tensile strength and hardness are respectively 870MPa and 266HB at about 1200°C. Moreover, the ballistic work and elongation are decreased with increasing the heating temperature. With respect to the microstructure transformation, it is found that the partial ferrite transforms to austenite when the heating temperature is above 900°C. And the martensite precipitates from the austenite during quenching process. While the heating temperature is above 1200°C, a great deal of high temperature δ-ferritic phase forms.
Now in its seventh edition, this accessible book provides readers with clear and concise discussions of key concepts while also incorporating familiar terminology. The author treats the important properties of the three primary types of materials (metals, ceramics, and polymers) and composites, as well as the relationships that exist between the structural elements of materials and their properties. Throughout, the emphasis is placed on mechanical behavior and failure, including techniques that are employed to improve performance.
Hard alloys are normally used as materials for excavators teeth in mining industry. In most cases these alloys do not have enough anti-wear properties and coatings are employed as a good alternative. The objective of this work is to test the abrasive wear resistance of several cast irons alloyed with different elements. Laboratory tests based on the ASTM G105-89 standard were compared to tests carried out under real working conditions of excavator teeth in mines.The experimental results show an acceptable correspondence between laboratory and field tests. To complete the laboratory research, hardness and microhardness measurements and optical micrographs were performed to identify the mechanism of wear. As a result of the experimental work, an economic evaluation of materials was also performed.
Abrasive wear is receiving increased attention particularly as its economic importance is appreciated. Low alloy carbon steels are widely used in the heat treated condition to resist abrasion and, in particular, are used for digger teeth. Little information is available in the literature on field or service wear studies and it was necessary, therefore, to carry out field studies in parallel with a laboratory wear investigation.A particular feature of the field study is the realization that significant wear occurs by rubbing to produce smooth surfaces and surface transformation, as well as wear by cutting and micro-chipping.A laboratory investigation based upon two-body pin-on-disc testing has been used to investigate the wear of a wide range of experimental steels, a manganese steel and a commercial digger tooth steel for comparison. Wear is directly proportional to the load and inversely related to hardness, but not to sliding distance because of the degradation of the abrasive paper. Abrasion increases with harder abrasives and increased abrasive particle size.The analysis of these results, although important from a wear mechanism point of view, shows that there is currently a lack of direct correlation between the field and laboratory studies because of the different surface features developed. Further investigations are proceeding to improve this correlation.
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