Cutting performance and wear mechanisms of Sialon ceramic cutting tools at high speed dry turning of gray cast iron

2016 ◽  
Vol 54 ◽  
pp. 330-334 ◽  
Author(s):  
Guizhao Tu ◽  
Shanghua Wu ◽  
Jia Liu ◽  
Ying Long ◽  
Bo Wang
Keyword(s):  
Cast Iron ◽  
Wear Mechanisms ◽  
High Speed ◽  
Gray Cast Iron ◽  
Cutting Tools ◽  
Cutting Performance ◽  
Gray Cast ◽  
Dry Turning ◽  
Sialon Ceramic

α-SiAlON: Development and Machining Test on Gray Cast Iron

2008 ◽  
Vol 591-593 ◽  
pp. 565-571 ◽  
Author(s):  
Olivério Moreira Macedo Silva ◽  
Maria do Carmo de Andrade Nono ◽  
José Vitor C. Souza ◽  
M.V. Ribeiro
Keyword(s):  
Cast Iron ◽  
Cutting Tool ◽  
Gray Cast Iron ◽  
Cutting Tools ◽  
Grey Cast Iron ◽  
Gray Cast ◽  
Machining Parameters ◽  
Ceramic Cutting Tool ◽  
Sialon Ceramic ◽  
Grey Cast

The α-SiAlON ceramic cutting tool insert is developed. Silicon nitride and additives powders are pressed and sintered in the form of cutting tool inserts at temperature of 1900 oC. The physics and mechanical properties of the inserts like green density, weight loss, relative density, hardness and fracture toughness are evaluated. Machining studies are conducted on grey cast iron workpiece to evaluate the performance of α-SiAlON ceramic cutting tool. In the paper the cutting tool used in higher speed showed an improvement in the tribological interaction between the cutting tools and the grey cast iron workpiece resulted in a significant reduction of flank wear and roughness, because of better accommodation and the presence of the graphite in gray cast iron. The above results are discussed in terms of their affect at machining parameters on gray cast iron.

scholarly journals Tool Wear Mechanisms of pcBN tooling during High-Speed Machining of Gray Cast Iron

Procedia CIRP ◽  
2018 ◽  
Vol 77 ◽  
pp. 606-609 ◽  
Author(s):  
Fredrik Schultheiss ◽  
Volodymyr Bushlya ◽  
Filip Lenrick ◽  
Daniel Johansson ◽  
Stefan Kristiansson ◽  
...  
Keyword(s):  
Cast Iron ◽  
Tool Wear ◽  
Wear Mechanisms ◽  
High Speed ◽  
Gray Cast Iron ◽  
Gray Cast ◽  
High Speed Machining ◽  
Tool Wear Mechanisms

Cutting Performance of Reaming Alloy Gray Cast Iron HT250 Using Carbide, Cermet and CBN Reamers

2018 ◽  
Vol 764 ◽  
pp. 261-270 ◽  
Author(s):  
X.K. Yang ◽  
Y.G. Wang ◽  
W.L. Ge ◽  
L. Chen ◽  
H. Ge
Keyword(s):  
Surface Roughness ◽  
Cast Iron ◽  
Tool Life ◽  
Gray Cast Iron ◽  
Cutting Parameters ◽  
Hole Diameter ◽  
Cutting Performance ◽  
Gray Cast ◽  
Suitable Material ◽  
Spindle Power

Cutting performance of reaming alloy gray cast iron HT250 using carbide, cermet and CBN reamers was studied. Experiments were conducted under constant cutting parameters and cooling strategy. Tool life, hole diameter, spindle power, surface roughness and tool wear were analyzed. The hole diameter and spindle power would keep steady when reaming with carbide reamer after 400 holes to the tool life of 1050 holes. But holes diameter reduced and spindle power increased with the number of machined holes increasing during the whole tool life when using cermet or CBN reamer. The surface roughness Rz of the holes reamed by carbide reamer was within the tolerance, although it was worse than that reamed by cermet and CBN reamer. It can be summarized that the carbide was the most suitable material for reaming alloy gray cast iron because of the longest tool life, steady hole diameter and spindle power, qualified surface roughness. After machining, crater wear and clearance wear were produced on the cermet and CBN reamer, which were caused by abrasive wear. In addition, flaking and breakages appeared on the edge of cermet reamer, which were not found on CBN reamer. However, the clearance wear of carbide reamer was smaller than that of CBN reamer, and built up edge was found along the cutting edge.

Surface Integrity of a High Speed Milling FC300 Gray Cast Iron

2013 ◽  
Vol 465-466 ◽  
pp. 642-646 ◽  
Author(s):  
Abu Bakar Mohd Hadzley ◽  
Mohamad Raffi Nurul Fatin ◽  
Raja Abdullah Raja Izamshah ◽  
Nur Izan Syahriah Hussein ◽  
Ahmad Siti Sarah ◽  
...  
Keyword(s):  
Cast Iron ◽  
Automotive Industry ◽  
High Speed ◽  
Gray Cast Iron ◽  
Gray Cast ◽  
Surface Finishing ◽  
High Speed Machining ◽  
High Productivity ◽  
Die Surface ◽  
End Mills

The high speed machining (HSM) of gray cast iron for manufacture mold and dies involve many different cutting tool from deep hole drills to smallest ball nose end mills [. Due to the demand of fast and high productivity, high speed machining (HSM) has been increasingly used to produce mold and dies that are mostly used in automotive industry especially for stamping dies components. The process of HSM sometimes combined together with manual polishing to enhance the die surface into fine mirror finish. Although the manual polishing strongly depends by experience and skill of workers, this technique is the preferable option for polishing of moulds and dies. However, such extensive manual polishing will provide some drawback because of many human factors such as pressure and technique of polishing individual person uses. Therefore, the application high speed machining in manufacturing is still demanding as it can improve surface finishing by reducing manual polishing, reportedly account for up to 30% of the total time [2].

Cutting Performance of Diamond Coated Si3N4 Tool During Turning

2010 ◽  
Vol 660-661 ◽  
pp. 106-111
Author(s):  
José Vitor C. Souza ◽  
Maria do Carmo de Andrade Nono ◽  
João Paulo Barros Machado ◽  
Olivério Moreira Macedo Silva ◽  
F.C.L. Melo ◽  
...  
Keyword(s):  
Cast Iron ◽  
Gray Cast Iron ◽  
Cutting Tools ◽  
Gray Cast ◽  
Depth Of Cut ◽  
Cast Irons ◽  
Hard Materials ◽  
Tool Wear Mechanisms ◽  
Cutting Length ◽  
Machining Operations

Silicon nitride cutting tools have been used successfully for machining hard materials, like: cast irons, nickel based alloys, etc. However these cutting tools with diamond coating present little information on dry turning operations of gray cast iron. In the present work, Si3N4 square inserts was developed, characterized and subsequently coated with diamond for dry machining operations on gray cast iron. All experiments were conducted with replica. It was used a 1500, 3000, 4500 m cutting length, feed rate of 0.33 mm/rev and keeping the depth of cut constant and equal to 1 mm. The results show that wear in the tool tips of the Si3N4 inserts, in all cutting conditions, was caused by both mechanical and chemical processes. To understand the tool wear mechanisms, a morphological analysis of the inserts, after experiments, has been performed by SEM and optical microscopy. Diamond coated PVD inserts showed to be capable to reach large cutting lengths when machining gray cast iron.

Diffusion Studies Involving Nanometric and Submicrometric Based Alumina Composites with Gray Cast Iron

2010 ◽  
Vol 65 ◽  
pp. 45-49 ◽  
Author(s):  
Karolina Pereira Santos Tonello ◽  
Vânia Trombini Hernandes ◽  
Ana Helena Almeida Bressiani ◽  
José Carlos Bressiani
Keyword(s):  
Grain Size ◽  
Cast Iron ◽  
Chemical Stability ◽  
Wear Mechanisms ◽  
Cutting Tool ◽  
Gray Cast Iron ◽  
High Fracture Toughness ◽  
Gray Cast ◽  
Second Phase ◽  
Machining Processes

Machining processes require tool materials with properties such as high hardness at elevated temperature, high fracture toughness and chemical stability with the workpiece. Advances in science and industry, as well as the development of harder materials have permitted cutting tool technology to evolve. In cutting processes, the contribution of different wear mechanisms to total wear is related to the mechanical and chemical properties of the two materials in contact. The high temperatures at tool-workpiece contact zones often result in diffusion of material from the workpiece to the cutting tool. Diffusion experiments were carried out to understand wear mechanisms involved at cutting edges of ceramic tools and the influence of microstructure on diffusion without the interference of mechanical wear processes. The chemical stability was analyzed from static interaction couple experiments at 1100°C with ceramic composite materials and gray cast iron. To investigate the influence of grain size on diffusion, sub-micrometric and nanometric alumina based composites with NbC as the second phase were used. These experiments showed that the influence of grain size on diffusion and the relative inertness of the composites in the presence of gray cast iron.

Generation of Wear Protective Layer in High Speed Turning of Gray Cast Iron Containing Aluminium and Magnesium

2009 ◽  
Vol 407-408 ◽  
pp. 500-503 ◽  
Author(s):  
Satoshi Furuya ◽  
Nobuaki Ozoe ◽  
Yasuo Yamane
Keyword(s):  
Cast Iron ◽  
Tool Wear ◽  
High Speed ◽  
Gray Cast Iron ◽  
Cutting Speed ◽  
Protective Layer ◽  
Gray Cast ◽  
Nitride Ceramics ◽  
Tool Surface ◽  
Coated Carbide

This paper focuses on the influence of difference of tool materials on generation of wear protective layer when turning gray cast iron containing Al and Mg. In this experiment, the gray cast iron to which small quantities of Al and Mg was added were cut with cermet, P grade carbide (P10), silicon nitride ceramics (Si3N4), titanium nitride (TiN) coated carbide and K grade carbide (K10) at high speed. In turning gray cast iron containing Al and Mg with cermet, the tool wear was significantly reduced compared to that resulting from the cutting of conventional gray cast iron. Further, the protective layer consisting of nonmetallic inclusions in the work material was formed on the tool surface. In addition to cermet, this layer was formed on tool surface of Si3N4 and TiN coated carbide. The elements of Al and Mg added to the work materials were detected in the layers formed on these tool surfaces as well as cermet. The inhibiting effect on tool wear was also caused when turning with P10. However, P10 had much greater wear than cermet. On the other hand, in the case of turning with K10, the effect reducing wear with the addition of Al and Mg was not caused. The wear increased as cutting speed increased regardless of work materials.

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