Numerous phenomena that occur during the process of machine parts’ regeneration have a significant impact on the loss of their working ability. Therefore, the properties of the working surfaces of the teeth flanks of repaired gears were analyzed in this research. The hereditary properties of the gear teeth are expressed by the interdependence of their geometric and physical-mechanical-metallurgical parameters created during the technological operations of regeneration of worn teeth by welding/hard-facing. The hard-facing was executed with three filler metal types, namely: combination Inox 18/8/6 + EDur 600, Castolin 2 and UTP 670. The tested properties included geometrical accuracy, microstructure and microhardness. Evaluation of the executed regeneration procedures was done by comparing the mentioned parameters of the regenerated gears and the new ones. The tested gears were not withdrawn from production due to damage, but they were newly manufactured and intentionally damaged gears, made of the same materials, subjected to the same manufacturing process. In this way, all influences except for the considered filler metal type were eliminated. Based on results of the conducted experiments, it was possible to establish the influence of the filler metal type on the surface characteristics of the regenerated gears’ teeth flanks.

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Purpose The purpose of this study is to show which filler metal is the best for hard facing. Because the quality of the surface layer has a great influence on the working life of parts, the purpose was to extend the working life of parts exposed to intensive wear. The tested hard-faced models were made of low carbon steel to save the expensive base metal and to analyze the possibilities of extending the service life of existing structural parts. Design/methodology/approach Samples were prepared from plates hard faced with various filler metals. Samples were then subjected to experimental testing – testing of tribological properties and hardness and microstructure. Testing was done in conditions similar to real ones – with a sliding speed of 0.25, 0.5 and 1 m/s and with a load of 50, 75 and 100 N and in most rigorous dry conditions. Research was done by using a combination of experimental and theoretical approaches. Findings The paper shows the results of the experimental testing of four different filler metals aimed for hard facing of parts exposed to highly intensive wear. Results shown that CrWC 600 alloy is the most favorable filler metal for hard facing of parts such as those of construction mechanization and those subjected to intensive abrasive wear at stone mines. Practical implications All obtained results are real and fully applicable, as there is a huge industrial need for these types of technologies. With the application of these technologies, beside money savings, the working life of parts can be significantly extended. Originality/value The research presented in this paper was conducted because of the lack of results from this area in Serbia and because of the necessity for application of obtained results in companies for road maintenance and stone excavation in the region of Šumadija, Serbia.

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Purpose The purpose of this paper is comparison of experimental values of the drawing forces to numerical values in different contact conditions, taking into account the appearance of galling which occurs due to of difficult drawing process conditions. Design/methodology/approach The following two research approaches are used in this paper – the physical modeling, realized by the laboratory experiment, and the numerical simulation of the ironing drawing process. By analyzing the obtained results, the technique of physical modeling, with help of the laboratory equipment and numerical simulation by application of the finite element method, can be successfully used in studying the thin sheet ironing – strip drawing process. Findings It is significant to compare values of the deformation forces obtained by physical experiment to values obtained by the numerical simulation. In that way, it is possible to compare applied contact conditions (four lubricants in that case) and estimate matching of experimentally and numerically obtained results of the deformation forces. Presented results point out very good technological characteristics of ecologically friendly lubricant (single-bath) and grease based on MoS2. Significant decrease of the deformation force was achieved by its application, as well as maintaining of the lubricant’s layer during the forming process and almost complete elimination of galling on the contact. Practical implications Numerical analysis of stresses in the working piece wall, during the thin sheet strip drawing, requires precise values of the friction coefficient. It is an important indicator because one can define the contact conditions as the input data for the numerical simulation, based on its values for each type of lubricants and each value of the compressive lateral force. Originality/value The environmentally friendly lubricant tested exhibits a more favorable distribution of the drawing force during the process, mainly in experimental case. Grease based on MoS2 has good lubricating properties but that lubricant is conventional and environmentally unacceptable. Ecologically friendly lubricant can be successfully used in real ironing strip drawing process especially for high values of holding force achieving an increased tool life.

This paper presents the results of voluminous experimental investigations conducted to analyze the influence of the welding procedure on the performance of regenerated gears. Cylindrical spur gears were tested, both newly manufactured and regenerated, in two fundamentally different ways: by hard facing (surfacing) with the “hard” filler metal (DUR 600-IG) and with the “soft” filler metal (EVB2CrMo) with subsequent cementation and quenching. The regeneration procedures were defined and executed, while, subsequently, the microstructure and microhardness of the hard-faced layers were established and measured, followed by checking the durability of the hard-faced teeth flanks. Finally, techno-economic analysis was performed to establish the rationality of the conducted regenerations, i.e., the costs of regenerated and newly manufactured teeth were compared. Based on the results of the conducted investigations, it was possible to establish the influence of the welding type on the performance characteristics (primarily the service life) of the regenerated gears. For individual reparatory hard facing, the procedure with the “hard” filler metal exhibited better characteristics, while for batch reparation of numerous damaged gears, the reparation with the “soft” filler metal, followed by cementation and heat treatment, might be more convenient.

The possibilities for reparation by hard facing of the damaged working parts -the hammers of the secondary stones crusher are investigated in this paper. The analyzed crusher is stationary and it belongs into a group of the process equipment aimed for producing the crushed stone. The produced stone is later used for manufacturing various construction materials like asphalt, concrete, etc. Wear of the crusher's working parts occurs during the exploitation due to operation with very hard materials. That wear is usually abrasive and of high intensity what causes failure of the working parts and consequently the machine's downtimes and appearance of various types of losses, primarily financial ones. To prevent that, and to reduce the downtimes as well, one uses reparation technologies, one of which is hard facing. The analysis of the mass losses of the hard faced parts, after certain number of hours of the crusher's field operation, is performed in this paper.

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