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 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

An Experimental Study of Wear Mechanism on High Speed Machining of FC300 Gray Cast Iron Using TiAlN Coated Carbide Cutting Tool

2015 ◽  
Vol 761 ◽  
pp. 257-261 ◽  
Author(s):  
M.R. Nurul Fatin ◽  
A.B. Mohd Hadzley ◽  
Raja Abdullah Raja Izamshah ◽  
M.A. Amrand
Keyword(s):  
Experimental Study ◽  
Cast Iron ◽  
Wear Mechanism ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Tool ◽  
Gray Cast Iron ◽  
Gray Cast ◽  
Carbide Cutting Tool ◽  
Coated Carbide

This paper presents an experimental study of wear mechanism on high speed milling of FC300 gray cast iron using TiAlN coated carbide cutting tool. The experiment was carried out under dry cutting condition with different cutting speed (95-143m/min) and feed rate (4000-7000 mm/min). The cutting tool for machining FC300 gray cast iron is a ball nose end mill ø32 mm coated with TiAlN. Wear mechanism was analyzed at VB 0.08mm after 60 minute machining. The flank wear increased when the spindle speed and feed rate increased caused by the generated high shearing force and high cutting temperature. The dominant wear mechanisms appear to be the abrasion, adhesion, chipping and delaminating of coating at the contact surface of cutting tool. Formation of built-up edge (BUE) was evidence for most of the cutting trials.

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].

Machinability of Pearlitic Cast Iron With Cubic Boron Nitride (CBN) Cutting Tools

2002 ◽  
Vol 124 (4) ◽  
pp. 820-832 ◽  
Author(s):  
Jiancheng Liu ◽  
Kazuo Yamazaki ◽  
Hiroyuki Ueda ◽  
Norihiko Narutaki ◽  
Yasuo Yamane
Keyword(s):  
Cast Iron ◽  
Boron Nitride ◽  
Tool Wear ◽  
High Speed ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machining Conditions ◽  
Machining Center

In order to increase the accurate finishing productivity of pearlitic cast iron, face milling by CBN (Cubic Boron Nitride) cutting tools was studied. The main focus of the study is the machinability investigation of pearlitic cast iron with CBN cutting tools by studying the relationships among machining conditions such as feed rate, cutting speed as well as CBN cutting tool type, tool wear, workpiece surface quality, cutting forces, and cutting temperature. In addition, an emphasis is put on the effect of Al additive in pearlitic cast iron on its machinability and tool wear characteristics. High-speed milling experiments with CBN cutting tools were conducted on a vertical machining center under different machining conditions. The results obtained provide a useful understanding of milling performance by CBN cutting tools.

Machinability by Milling of Gray Cast Iron

2014 ◽  
Vol 657 ◽  
pp. 88-92
Author(s):  
Traian Grămescu ◽  
Constantin Cărăușu
Keyword(s):  
Cast Iron ◽  
High Speed ◽  
Gray Cast Iron ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Empirical Models ◽  
Major Influence ◽  
Iron Castings ◽  
Milling Tool ◽  
Grey Iron

In the laboratory of cutting machining technologies from the “Gheorghe Asachi” Technical University of Iaşi, a series of investigations on the machinability of cast iron samples having various structures were designed and developed. The aim of the research was to know and to explain the way in which various constituents of some iron castings exert influence on the degree of wear of a milling tool made of high speed steel. Within this research, mathematical empirical models were determined, in order to calculate the cutting speed v60, considered as an indicator for the evaluation of machinability. The research allowed establishing the factors able to have a major influence on tool wear phenomenon and obtaining thus a more complete image concerning the machinability of grey iron used for castings.

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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