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Effect of carbide promoting elements on CGI material processing
KTH, Skolan för industriell teknik och management (ITM), Industriell produktion, Maskin- och processteknologi.
KTH, Skolan för industriell teknik och management (ITM), Industriell produktion, Maskin- och processteknologi.
Scania CV AB, Materials Technology.
2010 (Engelska)Ingår i: Proceedings of the CIRP 2nd International Conference Process Machine Interactions, 2010Konferensbidrag, Publicerat paper (Refereegranskat)
Abstract [en]

Due to environmental regulations, the industry uses both new and recycled material for the casting of new components. In the heavy truck industry, great effort is put into the purchasing of “good quality” recycled/scrap material to be used for casting CGI (compacted graphite iron) cylinder blocks and cylinder heads. Scrap material with a large concentration of carbide promoting elements reduces the machinability drastically due to carbides. The effect of carbide promoting elements on CGI machinability needs to be investigated in order to produce high quality engine components in an economically satisfactory way. This study presents the effect of the carbide promoting elements of chromium, manganese and molybdenum on CGI material processing. 17 unique CGI materials with different material chemical composition were studied. Material testing, milling experiments and image analysis of microstructure were performed on all materials, mapping the process machine interaction. The results show that all carbide promoting elements, but especially chromium, reduce the tool life in CGI milling. The results also illustrate the interaction between concentration of carbide promoting elements, material strength and machinability.

Ort, förlag, år, upplaga, sidor
2010.
Nyckelord [en]
Milling, Carbides, Carbide Promoting Elements, Scrap Material, compacted
Nationell ämneskategori
Produktionsteknik, arbetsvetenskap och ergonomi
Forskningsämne
SRA - Produktion
Identifikatorer
URN: urn:nbn:se:kth:diva-27734ISBN: 978-0-9866331-0-2 (tryckt)OAI: oai:DiVA.org:kth-27734DiVA, id: diva2:380451
Konferens
CIRP 2nd International Conference on Process Machine Interactions, Vancouver
Forskningsfinansiär
XPRES - Initiative for excellence in production research
Anmärkning
QC 20110105Tillgänglig från: 2010-12-21 Skapad: 2010-12-21 Senast uppdaterad: 2011-11-21Bibliografiskt granskad
Ingår i avhandling
1. Criteria for Machinability Evaluation of Compacted Graphite Iron Materials: Design and Production Planning Perspective on Cylinder Block Manufacturing
Öppna denna publikation i ny flik eller fönster >>Criteria for Machinability Evaluation of Compacted Graphite Iron Materials: Design and Production Planning Perspective on Cylinder Block Manufacturing
2011 (Engelska)Doktorsavhandling, sammanläggning (Övrigt vetenskapligt)
Abstract [en]

The Swedish truck industry is looking for new material solutions to achieve lighter engines with increased strength to meet customer demands and to fulfil the new regulations for more environmentally friendly trucks. This could be achieved by increasing the peak pressure in the cylinders. Consequently, a more efficient combustion is obtained and the exhaust lowered. This, however, exposes the engine to higher loads and material physical properties must therefore be enhanced. One material that could meet these demands is Compacted Graphite Iron (CGI). Its mechanical and physical properties make it ideal as cylinder block material, though there are drawbacks concerning its machinability as compared to other materials that are commonly used for the same purpose. Knowledge about machining of the material and its machinability is consequently inadequate.

The main goal of this thesis is to identify and investigate the effect of the major factors and their individual contributions on CGI machining process behaviour. When the relationship between the fundamental features; machinability, material microstructure, and material physical properties, are revealed, the CGI material can be optimized, both regarding the manufacturing process and design requirements. The basic understanding of this is developed mainly through experimental analysis as, e.g., machining experiments and material characterization.

The machining model presented in this thesis demonstrates the influence of material and process parameters on CGI machinability. It highlights machinability from both design and production planning perspectives. Another important objective of the thesis is an inverse thermo−mechanical FE model for intermittent machining of CGI. Here, experimental results obtained from a developed simulated milling method are used as input data, both to calibrate and validate the model. With these models, a deeper understanding is obtained regarding the way to achieve a stable process, which is the basis for future optimization procedures. The models can therefore be used as a foundation for the optimization of CGI component manufacturing.

Ort, förlag, år, upplaga, sidor
Stockholm: KTH Royal Institute of Technology, 2011. s. xiii, 75
Serie
TRITA-IIP, ISSN 1650-1888 ; 2011-10
Nyckelord
Metal Cutting, Compacted Graphite Iron (CGI), Machinability, Design of Experiments (DoE), Inverse Finite Element (FE) Modelling, Simulated Milling Method
Nationell ämneskategori
Produktionsteknik, arbetsvetenskap och ergonomi
Forskningsämne
SRA - Produktion
Identifikatorer
urn:nbn:se:kth:diva-48430 (URN)978-91-7501-159-2 (ISBN)
Disputation
2011-12-02, F3, Lindstedtsväg 26, KTH, Stockholm, 09:00 (Engelska)
Opponent
Handledare
Projekt
MERA - OPTIMA CGIFFI - OPTIMA phase two
Forskningsfinansiär
XPRES - Initiative for excellence in production research
Anmärkning

QC 20111121

Tillgänglig från: 2011-11-21 Skapad: 2011-11-18 Senast uppdaterad: 2017-05-23Bibliografiskt granskad

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Berglund, AndersNicolescu, Cornel Mihai
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