An Investigation of Optimum Cutting Conditions in Face Milling Nodular Cast Iron FCD 400 Using Carbide Tool

To determine the effects of cutting conditions on flank adhesion, nodular cast iron grade 60 was machined dry and wet with carbide cutting tools K6, cast iron cutting grade, and K4H, steel cutting grade. Decreasing the feed rate raised the critical cutting speed at which flank build-up occurred and lowered the resultant tool force. For tools with positive rake angle, the critical cutting speed was generally higher and tool forces were lower than for tools with negative rake angle. A clearance angle of 15 deg eliminated flank adhesion, as did the use of cutting fluids. Flank build-up was analyzed chemically and metallurgically. Methods to prevent flank adhesion are recommended.

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Wear Characteristics of Coated Carbide Tools in the Face Milling of Ductile Cast Iron

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.749.178 ◽

2017 ◽

Vol 749 ◽

pp. 178-184 ◽

Cited By ~ 1

Author(s):

Israel Martinez ◽

Ryutaro Tanaka ◽

Yasuo Yamane ◽

Katsuhiko Sekiya ◽

Keiji Yamada ◽

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Keyword(s):

Cast Iron ◽

Flank Wear ◽

Ductile Cast Iron ◽

Face Milling ◽

Carbide Tool ◽

Coated Tools ◽

Coated Carbide Tool ◽

The Face ◽

Coated Carbide ◽

Coated Carbide Tools

This study reports an experimental investigation about the wear behavior of TiN and TiCN coated carbide tools during the face milling of pearlitic and ferritic ductile cast iron. Pearlitic ductile cast iron caused the highest cutting forces and flank wear in both TiN and TiCN coated tools. Due to its protective effect, the TiCN coated carbide tool outperformed the TiN coated carbide tool regarding flank wear. The main issue when face milling ferritic ductile cast iron with TiN coated tools was notching wear. The principal reason for notch wear was pointed as adhesive wear caused for the high tendency of ferrite to adhere on the tool. The results demonstrated that the TiCN coating did not showed notching wear when face milling ferritic ductile cast iron, therefore a good choice of coating material can prevent notching wear.

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Optimization of Cutting Parameters for Face Milling of Cast Iron by Reducing Specific Cutting Energy and Machined Surface Roughness

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.727-728.339 ◽

2015 ◽

Vol 727-728 ◽

pp. 339-344 ◽

Cited By ~ 2

Author(s):

Melissa Schlüter ◽

Henrique Butzlaff Hübner ◽

André João de Souza

Keyword(s):

Cast Iron ◽

Nodular Cast Iron ◽

Cutting Parameters ◽

Face Milling ◽

Depth Of Cut ◽

Machined Surface ◽

Controllable Factors ◽

Input Parameters ◽

Machined Surface Roughness ◽

Optimization Of Cutting Parameters

The search for continuous improvement of the processes and products offered to the market combined with continuous efforts to reduce energy consumption stimulates the development of techniques and tools geared towards their optimization. Thus, this manuscript describes the application of multivariate optimization in the process of face milling of DIN GGG 50 nodular cast iron by means of experimental design techniques, regression models, and Taguchi loss function. Three input parameters (axial “ap” and radial “ae” depth of cut, and feed-rate “f”) were used as controllable factors of the process and two output parameters (specific cuttingenergy “es” and roughnessaverage “Ra”) were considered as response variables. The output obtained as a result of optimization wases= 1.41 J/mm3andRa= 0.85 µm by applying the input parametersap= 2.34 mm,ae= 33.4 mm andf= 0.44 mm/rev.

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