Critical assessment of compacted graphite cast iron machinability in the milling process

Silva, L.R.R. da; Souza, Felipe Chagas Rodrigues de; Guesser, Wilson Luiz; Jackson, M. J.; Machado, Álisson Rocha

doi:10.1016/j.jmapro.2020.04.061

Cited by 36 publications

(11 citation statements)

References 12 publications

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“…The CGI C material showed slightly inferior machinability than CGI B, with the probable explanation caused by the presence of Mo carbides, which, due to their high hardness (Figure 3(d)), increases the average hardness of the material (Figure 3(c)), thus increasing the tool wear. The correlation between the tool life and the mechanical properties of the graphitic cast irons was also observed in a similar trend by Da Silva et al 22 in the drilling process and Da Silva et al 23…”

Section: Resultssupporting

confidence: 81%

Tool wear monitoring in drilling of high-strength compacted graphite cast irons

Silva

Claro

Andrade³

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Machining is such a complex system that any foreseen result is practically impossible. However, research always helps to further understand the process, which contributes to providing positive results. Tool wear is always difficult to foresee, but it can be measured and related to several output parameters. In each individual application, there will be the best parameter that most reliably represents the tool wear. In the present investigation, the hole quality parameters (roughness and cylindricity), power consumption, electrical consumption of the machine tool and the acoustic emission signals were recorded and correlated to the tool condition in order to find the best output parameter for tool wear monitoring during the drilling of compact graphite cast irons. Two high-strength grades of compacted graphite cast irons (both CGI 500 with changes in the matrix and graphitic structure) were machined and compared to the standard grade (CGI 450) usually used in the manufacturing of engines using TiAlN-coated carbide drills at a constant cutting condition. The results showed that the best output parameter to monitor the tool wear was the electric current signal.

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Section: Resultssupporting

confidence: 81%

Tool wear monitoring in drilling of high-strength compacted graphite cast irons

Silva

Claro

Andrade³

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…6.b presented an inverse correlation of -97%. This inverse correlation can be explained as a more stable chip formation can be achieved as the mechanical properties of the material increase, mainly due to the graphite refinement in both CGIs B and C, as also observed by (Da Silva et al, 2020). Another possible explanation is that the lower machining temperatures resulted in more stiffness of the matrix during the shearing process, thus reducing the open grain phenomenon.…”

Section: Resultsmentioning

confidence: 65%

“…After the tests, the surface roughness was measured using a surface profiler model S100 manufactured by Taylor Hobson®, and the resulting machined surface was evaluated in relation to the average surface roughness (Ra). All the calibrations and test patterns were made according to the ones performed by da Silva et al (2018).…”

Section: Methodsmentioning

confidence: 99%

“…Due to the inherent complexity of machining processes, it is virtually impossible to predict the machinability of a system (Shaw, 1984). The superior mechanical properties of CGI in relation to aluminum and gray cast iron make the machining of this material a challenge, with this lower machinability being evidenced in the turning processes (Da Silva et al, 2020). This work aims to evaluate the correlation between the machining temperature with the mechanical and metallurgical properties, as well as with the machining power and surface roughness of three compacted graphite cast irons, one (CGI A) class 450 and the other two (CGIs B and C ) of class 500.…”

Section: Introductionmentioning

confidence: 99%

“…Microstructures of the materials evaluated.The lower figures are larger magnifications of the samples after attacks (Nital-2% for 15 seconds). Adapted from daSilva et al (2018).…”

mentioning

confidence: 99%

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Correlation Between Cutting Temperatures and Metallurgical Properties of Compacted Graphite Cast Irons in the End Milling Process

Silva

Machado

2021

RETERM

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In the search for more energy-efficient internal combustion engines, the automotive companies keep pushing the working temperatures and pressures of the engines, leading to more extreme working conditions and so the necessity of new materials. Among the most promising materials for the new generations of engines is the compacted graphite cast iron, which is more wear-resistant than aluminum and tougher than gray cast iron. However, this combination of properties also leads to decreased machinability, increasing production costs and, therefore, their market competitiveness. This paper evaluated the correlation of mechanical and metallurgical properties and the cutting power and surface roughness of three grades of compacted graphite cast iron with the cutting temperature in the end milling process under different two different feed rates and cutting speeds. This analysis showed that the temperatures near the cutting zone are closely correlated to the material's mechanical properties, machining power, and resulting roughness. These results indicate that thermographic images are a good indicator of the overall correlation between the changes in material properties and the most usual machinability output parameters.

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