Assessment of Machining Characteristics of Austempered Ductile Iron

2010 ◽  
Vol 97-101 ◽  
pp. 2036-2039 ◽  
Author(s):  
Ashwin Polishetty ◽  
Guy Littlefair
Keyword(s):  
Surface Texture ◽  
Ductile Iron ◽  
Cutting Parameters ◽  
Cutting Fluid ◽  
Austempered Ductile Iron ◽  
Spheroidal Graphite ◽  
Surface Texture Analysis ◽  
Machining Characteristics ◽  
Stage Heat Treatment ◽  
Cutting Speeds

Austempered Ductile Iron (ADI) is a modified Spheroidal Graphite Iron (SGI) produced by applying a two-stage heat treatment cycle of austenitising and austempering. The microstructure of ADI also known as “ausferrite” consists of ferrite, austenite and graphite nodules. Machining ADI using conventional techniques is often problematic due to the microstructural phase transformation from austenite to martensite. Machining trials consisted of drilling ADI-Grades900, 1050, 1200 and 1400 using inserted (TiAlN PVD coated) type drills. The cutting parameters selected were; cutting speeds [m/min] of 30 and 40; penetration rates [mm/rev] of 0.1 and 0.2; to a constant depth of 20mm. The machining characteristics of ADI are evaluated through surface texture analysis and microhardness analysis. These results indicate that microhardness is modified during machining and surface texture is improved using a cutting fluid.

Studying The Effect of a New Mixed Cutting Fluid on Surface Roughness

2020 ◽  
Vol 38 (11A) ◽  
pp. 1593-1601
Author(s):  
Mohammed H. Shaker ◽  
Salah K. Jawad ◽  
Maan A. Tawfiq
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Dry Cutting ◽  
Cutting Speeds

This research studied the influence of cutting fluids and cutting parameters on the surface roughness for stainless steel worked by turning machine in dry and wet cutting cases. The work was done with different cutting speeds, and feed rates with a fixed depth of cutting. During the machining process, heat was generated and effects of higher surface roughness of work material. In this study, the effects of some cutting fluids, and dry cutting on surface roughness have been examined in turning of AISI316 stainless steel material. Sodium Lauryl Ether Sulfate (SLES) instead of other soluble oils has been used and compared to dry machining processes. Experiments have been performed at four cutting speeds (60, 95, 155, 240) m/min, feed rates (0.065, 0.08, 0.096, 0.114) mm/rev. and constant depth of cut (0.5) mm. The amount of decrease in Ra after the used suggested mixture arrived at (0.21µm), while Ra exceeded (1µm) in case of soluble oils This means the suggested mixture gave the best results of lubricating properties than other cases.

scholarly journals Machinability and related properties of austempered ductile iron: A review

2018 ◽  
Vol 12 (4) ◽  
pp. 4180-4190
Author(s):  
Ananda Hegde ◽  
Sathyashankara Sharma ◽  
Gowri Shankar M. C
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Wear Resistance ◽  
Ductile Iron ◽  
High Hardness ◽  
Austempered Ductile Iron ◽  
Spheroidal Graphite ◽  
Light Weight ◽  
Sg Iron

When the ductile iron which is also known as Spheroidal Graphite (SG) iron, is subjected to austempering heat treatment, the material is known as austempered ductile iron (ADI). This material has good mechanical properties and has various applications in different fields. This revolutionary material with its excellent combination of strength, ductility, toughness and wear resistance has the potential to replace some of the commonly used conventional materials such as steel, aluminium and other light weight alloys as it offers production advantage as well. One of the problems encountered during manufacturing is machining of ADI parts owing to its high hardness and wear resistance. Many researchers over a period of time have reported the machinability aspects of the ADI. This paper presents a review on the developments made on the machinability aspects of ADI along with other mechanical properties.

Effect of Cutting Parameters on the Surface Residual Stress of Face-Milled Pearlitic Ductile Iron

2017 ◽  
Vol 4 (1) ◽  
pp. 38-52
Author(s):  
Olutosin Olufisayo Ilori ◽  
Dare A. Adetan ◽  
Lasisi E. Umoru
Keyword(s):  
Residual Stress ◽  
Fluid Flow ◽  
Flow Rate ◽  
Ductile Iron ◽  
Cutting Parameters ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Fluid Flow Rate ◽  
Surface Residual Stress ◽  
Average Surface

The study determined the effect of cutting parameters on the surface residual stress of face-milled pearlitic ductile iron with a view to enhancing surface integrity of machined parts in the manufacturing industries. The pearlitic ductile iron used for this study was prepared and four cutting parameters were considered. The results obtained showed that the average surface residual stress of the machined surfaces was tensile and increased significantly with increase in depth of cut. Feed rate and cutting speed exhibited some effect, though not statistically significant, on average surface residual stress. The average residual stress was found to decrease significantly and drastically from 605.39 MPa to 101.72 MPa as cutting fluid flow rate increased from 0 ?/min to 4 ?/min. The study concluded that out of all four cutting parameters investigated, the cutting fluid flow rate has most considerable influence on the surface residual stress of the machined pearlitic ductile iron.

Turning of Austempered Ductile Iron with ceramic tools

2020 ◽  
pp. 095440542095715 ◽  
Author(s):  
A Fernández-Valdivielso ◽  
LN López de Lacalle ◽  
P Fernández-Lucio ◽  
H González
Keyword(s):  
Heat Treatment ◽  
Tool Wear ◽  
Ductile Iron ◽  
High Strength ◽  
Cutting Parameters ◽  
Precise Determination ◽  
Machining Process ◽  
Austempered Ductile Iron ◽  
Machining Time ◽  
Ceramic Tools

Austempered ductile iron castings (ADI) are characterized by the high strength and resistance to fatigue, impact, and wear. ADI mechanical properties are obtained by performing a heat treatment on ductile iron casting. Thus, the so-called ausferrite microstructure is achieved. However, heat treatment significantly affects ductile casting machinability. A precise determination of ADI microstructure, on the one hand, and to choose correct machining process parameters and tool wear control on the other, are essential to optimize cutting processes and for the introduction of ceramic inserts. Ceramics are an alternative to carbide tools. In this paper, ceramic tools for the dry turning of ADI castings are studied. Thus, different technical ceramics were analyzed, identifying the dominant wear mechanism and evolution. Tool wear rate magnitude was determined indirectly by the variation of cutting force along machining time. Finally, different tests helped to study ceramics wear sensitivity with respect to cutting parameters. Mixed ceramics of Al2O3 with TiC showed the best performance, followed by SiAlON ones.

A Comparative Assessment of Austempered Ductile Iron as a Substitute in Weight Reduction Applications

2008 ◽  
Author(s):  
Ashwin Polishetty ◽  
Sarat Singamneni ◽  
Guy Littlefair
Keyword(s):  
Ductile Iron ◽  
High Performance ◽  
Material Selection ◽  
Weight Ratio ◽  
Cost Savings ◽  
High Strength ◽  
Good Choice ◽  
Comparative Assessment ◽  
Austempered Ductile Iron ◽  
Machining Characteristics

Manufacturing engineering has had to undergo drastic changes in the approach to material selection in order to meet new design challenges. In the automotive industry, researchers in their effort to reduce emissions and satisfy environmental regulations, have shifted their focus to new emerging materials such as high-strength aluminium alloys, metal matrix composites, plastics, polymers and of late, Austempered Ductile Iron (ADI). ADI is a good choice for design where the criterion is high performance at reduced weight and cost. The unique, ausferrite microstructure gives the material desirable material properties and an edge over other materials. A comparative study of ADI in terms of materials properties and machining characteristics with other materials is desirable to highlight the potential of the material. This paper focuses on a comparative assessment of material and machining characteristics of ADI for different applications. The properties under consideration are machinability, weight and cost savings and versatility. ADI has a higher strength-to-weight ratio than aluminium making it a ready alternative for material selection. In terms of machinability, there are some problems associated with machining of ADI due to its work hardening nature. This paper attempts to identify the possible potential applications of ADI, by critically reviewing specific applications such as machinability, overall economics and service.

The Effect of Build Up Edge Formation on the Machining Characteristics in Austempered Ferritic Ductile Iron

2013 ◽  
Author(s):  
Şakir Yazman ◽  
Ahmet Akdemir ◽  
Mesut Uyaner ◽  
Barış Bakırcıoğlu
Keyword(s):  
Surface Roughness ◽  
Ductile Iron ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Salt Bath ◽  
Chip Formation Mechanism ◽  
Machining Properties ◽  
Machining Characteristics ◽  
Cutting Speeds

In this study, chip formation mechanism during the machining of austempered ferritic DI and the effect of the emerging chip morphology on such machining properties as surface roughness and cutting forces has been scrutinized. After austenitizing at 900 °C for 90 min, DI specimens were austempered in a salt bath at 380 °C for 90 min. Chip roots were produced by using a quick stop device during the machining of austempered specimens in different cutting speeds. The metallographies of these specimens were performed and chip morphologies were examined. The fact that the cutting speed increased led to a decrease in built-up edge formation. Depending on this fact, it was detected that the change in built-up edge thickness substantially affected the surface roughness and cutting forces. It was also detected that during the machining, with the effect of cutting forces and stress, spheroidal graphites were broken off in the chip and lost their sphericity and so that the chip became fragile and unstable and grafites here displayed a lubricant feature.

scholarly journals Low Temperature Impact Tests in Austempered Ductile Iron and Other Spheroidal Graphite Cast Iron Structures.

2001 ◽  
Vol 41 (4) ◽  
pp. 372-380 ◽  
Author(s):  
P. J. J. Ratto ◽  
A. F. Ansaldi ◽  
V. E. Fierro ◽  
F. R. Agüera ◽  
H. N. Alvarez Villar ◽  
...  
Keyword(s):  
Cast Iron ◽  
Low Temperature ◽  
Ductile Iron ◽  
Austempered Ductile Iron ◽  
Spheroidal Graphite ◽  
Impact Tests ◽  
Spheroidal Graphite Cast Iron ◽  
Graphite Cast Iron ◽  
Temperature Impact

The Effects of Cutting Speed and Depth of Cut on Machinability Characteristics of Austempered Ductile Iron

2012 ◽  
Vol 134 (2) ◽  
Author(s):  
Ahmet Akdemir ◽  
Şakir Yazman ◽  
Hacı Saglam ◽  
Mesut Uyaner
Keyword(s):  
Surface Roughness ◽  
Ductile Iron ◽  
Flank Wear ◽  
Tangential Force ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Salt Bath ◽  
Austempered Ductile Iron ◽  
Dominant Factor ◽  
Depth Of Cut

Ductile iron can acquire enhanced thermal and mechanical properties from austempering heat treatment. The present study aims to identify the function of different cutting parameters affecting machinability and to quantify its effects. Turning was performed to test machinability according to the ISO3685-1993 (E) standard. After austenitizing at 900 °C for 90 min, austempered ductile iron (ADI) specimens were quenched in a salt bath at 380 °C for 90 min. The cutting force signals along three directions were measured in real time, whereas flank wear and surface roughness were measured offline. For the cutting parameters, the cutting speed and depth of cut were varied, but the feed rate was kept constant. In the flank wear tests, machining length was corresponded to tool life. In addition, in order to find out the effect of cutting parameters on surface roughness (Ra), tangential force (Ft), and flank wear (VB) during turning, response surface methodology (RSM) was utilized by using experimental data. The effect of the depth of cut on the surface roughness was negligible but considerable in the cutting forces. The increased cutting speed produced a positive effect on surface roughness. It is found that the cutting speed was the dominant factor on the surface roughness, tangential force, and flank wear.

scholarly journals Morphology and wear of high chromium and austempered ductile iron balls as grinding media in ball mills

2021 ◽  
Vol 2070 (1) ◽  
pp. 012201
Author(s):  
BRN Murthy ◽  
Ravichandra Rangappa
Keyword(s):  
Ductile Iron ◽  
Research Work ◽  
Milling Process ◽  
Austempered Ductile Iron ◽  
Spheroidal Graphite ◽  
Wear Loss ◽  
Ball Mills ◽  
High Chromium ◽  
Wear Rates ◽  
Grinding Media

Abstract High chromium balls are recognized as better grinding media in terms of wear rates than forged steel balls, which are conventional grinding media in the milling process of iron ore. In this research work, the wear rate of high chromium balls and austempered ductile iron (ADI) balls as crushing media in a ball mill are compared. ADI are prepared by austenitizing the spheroidal graphite (SG) iron balls at 920 °C for one hour, and step austempering heat treatments were given, which includes the first step austenitizing at 300 °C for 15 min, followed by a second step austenitizing at 400 °C for 60 min. The wear rates were estimated when both balls were used separately by maintaining the same machining conditions and when the balls are mixed. The grinding wear conduct of both materials is evaluated for wear loss in wet grinding conditions. The experimental results reveal that the performance of ADI balls is better than high chromium balls when tested separately and mixed. Results also indicate that the wear rates/revolutions will decrease when the operating period increases.

Influence of Technological Cutting Parameters on Surface Texture of Austenitic Stainless Steel

2014 ◽  
Vol 693 ◽  
pp. 430-435 ◽  
Author(s):  
Grzegorz M. Krolczyk ◽  
Stanislaw Legutko ◽  
Radoslaw W. Maruda
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Surface Texture ◽  
Austenitic Stainless Steels ◽  
Cutting Parameters ◽  
Geometrical Parameters ◽  
Deep Well ◽  
Primary Model ◽  
Coated Carbide ◽  
Surface Texture Analysis

The paper presents the contribution in engineering of surfaces particularly in surface texture of Austenitic Stainless Steels. The objective of the investigation was to determine the surface texture of austenitic stainless steel after turning with coated carbide tool point. The investigation included geometrical parameters of Surface Integrity for different technological cutting parameters in dry turning process of austenitic stainless steel. The article presents the surface roughness parameters with the roughness profiles (irregular slopes). The percentage of isotropic surfaces and Bearing Area of ​​Primary Model. Analyses were performed for variable cutting parameters. An Infinite Focus Measurement Machine (IFM) was used for the surface texture analysis. The study was performed within a production facility during the machining of electric motor parts and deep-well pumps.

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