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Analysis of Tool Wear in CGI Machining
Chalmers, Dept Mat & Mfg Technol.
KTH, School of Industrial Engineering and Management (ITM), Production Engineering.
Chalmers, Dept Mat & Mfg Technol.
KTH, School of Industrial Engineering and Management (ITM), Production Engineering.
2008 (English)In: IMETI 2008: INTERNATIONAL MULTI-CONFERENCE ON ENGINEERING AND TECHNOLOGICAL INNOVATION, VOL I, PROCEEDINGS, 2008, 34-39 p.Conference paper, Published paper (Refereed)
Abstract [en]

In this study the tool wear and wear mechanisms on coated cemented carbide inserts were investigated in turning of Compacted Graphite Iron (CGI) materials with different nodularity. Investigation of how small changes in nodularity affect the wear behaviour of inserts in CGI machining has not earlier been done. The inserts were examined in LOM, SEM and in EDX. The tool wear could on the basis of their wear appearance be classified in three different wear categories; A, B and C. In the wear category A, abrasive wear, adhesive wear and delamination wear could be seen. In the wear category B, the predominant wear mechanism was chipping. The wear appearance in wear category C indicated attrition wear and dissolution via diffusion. Classification of the wear mechanisms gave knowledge that could be used in tool design. The results showed that increasing nodularity has impact on wear at moderate and high cutting speed but not at lower cutting speed. Machining of all materials at high cutting speed, 400 m/min, led to complete degradation of the edge line. A small difference in nodularity from 5% to 20% has more significant impact on wear than from 20% to 62%. This seemed to be correlated with the difference in ultimate tensile strength between the materials.

Place, publisher, year, edition, pages
2008. 34-39 p.
Series
Trita-IIP, ISSN 1650-1888 ; 08-07
Keyword [en]
Compacted Graphite Iron, machining, tool wear, coated cemented carbides, nodularity
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
URN: urn:nbn:se:kth:diva-25922ISI: 000263828900007Scopus ID: 2-s2.0-84893180061OAI: oai:DiVA.org:kth-25922DiVA: diva2:360860
Conference
International Multi-Conference on Engineering and Technological Innovation, Orlando, FL, JUN 29-JUL 02, 2008
Note
QC 20101105Available from: 2010-11-05 Created: 2010-11-05 Last updated: 2010-11-05Bibliographically approved
In thesis
1. Characterization of factors interacting in CGI machining: machinability - material microstructure - material physical properties
Open this publication in new window or tab >>Characterization of factors interacting in CGI machining: machinability - material microstructure - material physical properties
2008 (English)Licentiate thesis, comprehensive summary (Other scientific)
Abstract [en]

The Swedish truck industry is forced to find new material solutions to achieve lighter engines with increased strength. Customers and new environmental regulations demand both higher specific power and more environmentally friendly trucks, and this places a rising pressure on the manufactures. This demand could be met 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.

Today, alloyed gray iron is the predominantly used engine material. This material cannot meet the requirements of tomorrow’s engines. Compacted Graphite Iron has good potential to be the replacement; it opens new design opportunities with its superior strength, which can lead to smaller, more efficient engines and additional power. The question is: how will manufacturing be affected?

The main goal of this thesis is to identify and investigate the main factors’ effect and their individual contributions on CGI machining.  When the relationship between the fundamental features; machinability, material microstructure, and material physical properties, are revealed, then the CGI material can be optimized, both regarding the manufacturing process and design requirements. The basic understanding is developed mainly through experimental analysis. No attempt has been made to optimize the material to be used as engine material in this thesis.

The thesis demonstrates the importance of having good casting process control. It also illustrates the microstructural properties’ effects on CGI machinability, and what new aspects of machining must be taken into account, compared to gray iron.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2008. ix, 43 p.
Series
Trita-IIP, ISSN 1650-1888 ; 08-11
Keyword
CGI, Compacted Graphite Iron, milling, cast iron, machinability, material microstructure, material physical properties, CGI, kompaktgrafitjärn, fräsning, gjutjärn, skärbarhet, mikrostruktur, materialegenskaper
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:kth:diva-9258 (URN)978-91-7415-158-9 (ISBN)
Presentation
2008-11-14, M311, Brinellsalen, Brinellvägen 68, Stockholm, 10:00 (Swedish)
Opponent
Supervisors
Projects
OPTIMA CGI
Note
QC 20101105Available from: 2008-11-07 Created: 2008-10-14 Last updated: 2011-05-19Bibliographically approved

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