With advancements in science and technology and the development of industrialization, the manufacturing process of rock drilling tools is continually improving. One important research direction is the intelligent control of the carburizing process. The carburizing process affects the hardness, wear resistance, and service life of rock drilling tools but is also directly related to rock drilling efficiency and cost. This article will discuss the main factors affecting the carburizing intelligence of rock drilling tools from multiple angles to help you better understand the technological innovation in this field.
Material selection
The material of rock drilling tools is the primary factor affecting the carburizing effect. Currently, there are mainly rock drilling tools made of low-carbon steel and high-carbon steel on the market. Low-carbon steel drilling tools are suitable for general rock drilling operations. However, for professional quarrying or construction industries, high-carbon steel drill tools are the first choice due to their higher hardness, sturdiness, wear resistance, and corrosion resistance. High carbon steel can form a deeper carburized layer during the carburizing process, significantly improving the performance of rock drilling tools.
Precise control of carburizing process parameters
Precise control of carburizing process parameters is the key to achieving intelligence. Carburizing temperature, carbon potential, and carburizing time are the core factors that affect the quality and depth of the carburized layer. When the carburizing temperature and carbon potential are high, the carburizing speed is fast, however, too high temperature or carbon potential may cause network carbides to appear on the surface of the carburized layer, increasing brittleness and notch sensitivity. Therefore, an intelligent control system is required to accurately monitor and adjust these parameters to ensure the optimal quality and depth of the carburized layer.
Application of intelligent control technology
Intelligent control technology dramatically improved the accuracy and stability of the carburizing process through simulation and actual feedback mechanisms. Studies have shown that intelligent carburizing process simulation has high accuracy, which is of guiding significance for the formulation of the carburizing process and can save a lot of test time and research costs. At the same time, intelligent control reduces the errors caused by human factors, provides timely feedback for carburizing simulation, and provides valuable experience for process design.
Synergy of heating and quenching process
The heating and quenching processes are essential processing steps after carburizing, which directly affect the final performance of the drilling tool. Medium-frequency induction heating has become the preferred method for quenching heating due to its uniform heating, fast speed, and low energy consumption. The surface hardness after quenching should reach HRC58 or higher to ensure the rock drilling tools’ wear resistance and service life. The tempering treatment adopts a low-temperature salt bath furnace, and the hardness after tempering is kept above HRC56 to balance the hardness and toughness.
Advancedness of heat treatment equipment
The performance of heat treatment equipment directly affects the intelligence level of the carburizing process. Advanced equipment, such as deep-well gas carburizing furnaces, provides a more stable and uniform carburizing environment, which aids in the intelligent control of the carburizing process. However, due to investment or resource constraints, some manufacturers may not be able to equip these high-end equipment and turn to other process routes, such as conventional quenching and tempering or isothermal quenching followed by tempering. These alternative processes often fall short in performance compared to advanced methods.
Production process and metallurgical quality of hollow steel
The production process and metallurgical quality of hollow steel significantly impact the quality and lifespan of threaded drill rods. Minimizing defects in the inner hole and outer surface or strengthening these areas can effectively enhance the drill rod’s service life. Therefore, it is crucial to control the production process of hollow steel to ensure that the metallurgical quality meets the standards, laying a solid foundation for the subsequent carburizing treatment.
Operator skill level
Although the carburizing process has been highly automated, the operator’s skill level still influences rock drilling tools’ final performance. Skilled operators can better control the rock drilling tools’ position, angle, and force to improve rock drilling efficiency. At the same time, they can also promptly detect and deal with problems that may arise during the carburizing process to ensure the smooth progress of the carburizing process.
Wear and maintenance
During rock drilling operations, the rock drilling tool constantly comes into contact with solid materials, leading to surface wear. Worn drilling tools not only decrease efficiency but also shorten their service life. Therefore, rock drilling tools should be inspected and maintained regularly. Restoring the flatness and finish of the drilling tool surface by cleaning, sanding, or grinding can extend its service life and maintain optimal performance.
Conclusion
In summary, many factors affect the intelligent carburizing of rock drilling tools, including material selection, precise control of carburizing process parameters, application of intelligent control technology, the synergy of heating and quenching processes, advancement of heat treatment equipment, production process, and metallurgical quality of hollow steel, the skill level of operators, wear and maintenance, etc. Only by comprehensively considering these factors and taking corresponding measures can the intelligent control of the carburizing process of rock drilling tools be realized, the performance and service life of the tools be improved, and the cost of use be reduced.
