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].

scholarly journals Wear Mechanism of PcBN Tool in High Speed Machining of Gray Cast Iron.

1998 ◽  
Vol 64 (2) ◽  
pp. 261-265 ◽  
Author(s):  
Kazuhiro SHINTANI ◽  
Hideharu KATO ◽  
Hiroaki SUGITA ◽  
Naohiko SUZUKI
Keyword(s):  
Cast Iron ◽  
Wear Mechanism ◽  
High Speed ◽  
Gray Cast Iron ◽  
Gray Cast ◽  
High Speed Machining ◽  
Pcbn Tool

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

scholarly journals Surface Quality Evaluation of Various Metals After Grinding with Aluminum Oxide Grinding Wheel

2020 ◽  
Vol 9 (1) ◽  
pp. 25-31
Author(s):  
Rosemar Batista Da Silva ◽  
Giordano Francis Vieira ◽  
Letícia Cristina Silva ◽  
Carlos Alberto Damião ◽  
Rodrigo De Souza Ruzzi ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cast Iron ◽  
Aluminum Oxide ◽  
Surface Quality ◽  
Gray Cast Iron ◽  
Gray Cast ◽  
Surface Finishing ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Machined Surfaces

Different metals can respond differently when grinding using the same abrasive grinding wheel, especially in terms of surface quality. In this context, this work aims give a contribution to the metalworking industry by presenting the results of surface finishing after grinding the following metals: VP Atlas steel grade, Gray Cast Iron and two superalloys, Inconel 718 and Ti-6Al-4V. Tests were performed with the aluminum oxide grinding wheel and with following parameters: cutting speed of 37.6 m/s and workspeed of 10 m/min. Two values of depth of cut (15 μm and 30 μm) were tested. The surface roughness (Ra and Rz parameters) were analyzed and SEM images of the machined surfaces were taken and analyzed in order to identify the cutting mechanisms and provide better results discussion. The results showed that the surface roughness increased with the depth of cut; Ra values kept below 0.48 μm for all metals tested. Regarding the machined surface quality, some cracks were observed on the gray cast iron and Ti-6Al-4V surfaces, thereby indicating their relative lower grindability compared to VP Atlas steel under the investigated conditions. No visual thermal damage was observed in the machined surfaces of the samples.

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.

scholarly journals High Speed Cutting of Gray Cast Iron and Steel with Al2O3-TiC Ceramics Tools.

1992 ◽  
Vol 39 (11) ◽  
pp. 1028-1032
Author(s):  
Toshiyuki Takahashi ◽  
Yuji Katsumura ◽  
Hirotaka Kiso ◽  
Hisashi Suzuki
Keyword(s):  
Cast Iron ◽  
High Speed ◽  
Gray Cast Iron ◽  
Gray Cast ◽  
Iron And Steel ◽  
High Speed Cutting

Surface Turbulence at Flow of Gray Cast Iron

2010 ◽  
Vol 457 ◽  
pp. 422-427 ◽  
Author(s):  
Attila Diószegi ◽  
Tobias Björklind ◽  
Zoltán Diószegi
Keyword(s):  
Cast Iron ◽  
High Speed ◽  
Gray Cast Iron ◽  
Liquid Surface ◽  
Gray Cast ◽  
Average Flow Velocity ◽  
Mould Filling ◽  
Surface Turbulence ◽  
Different Levels ◽  
Absorption Of Hydrogen

Gray cast iron has been investigated with respect to surface turbulence during mould filling. Different levels of flow velocities have been provoked in a vertically parted sand mould. The thermal resistant transparent front side of the mould permitted the observation of the flow pattern due to high speed camera registration. The registered frames including the liquid surface were investigated using image analyses. The results show good correlation between the average flow velocity and the liquid iron surface extension. Consequently it has been demonstrated that an increased absorption of hydrogen and nitrogen during mould filling is dependent on the level of liquid surface turbulence.

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