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The Effect of Interlamellar Distance in Pearlite on CGI Machining
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology.
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology.
Swerea SWECAST AB.
2009 (English)In: ICME 2009: International Conference on Mechanical Engineering, 2009, 33-44 p.Conference paper, Published paper (Refereed)
Abstract [en]

Swedish truck industry is investigating the possibilityfor implementing the use of Compacted Graphite Iron (CGI) in theirheavy duty diesel engines. Compared to the alloyed gray iron usedtoday, CGI has superior mechanical properties but not as goodmachinability. Another issue that needs to be addressed whenimplementing CGI is the inhomogeneous microstructure when thecast component has different section thicknesses, as in cylinderblocks. Thinner sections results in finer pearlite, in the material, withhigher strength. Therefore an investigation on its influence onmachinability was needed. This paper focuses on the effect thatinterlamellar distance in pearlite has on CGI machinability andmaterial physical properties. The effect of pearlite content andnodularity is also examined. The results showed that interlamellardistance in pearlite did not have as large effect on the materialphysical properties or machinability as pearlite content. The paperalso shows the difficulties of obtaining a homogeneousmicrostructure in inhomogeneous workpieces.

Place, publisher, year, edition, pages
2009. 33-44 p.
Series
PROCEEDINGS OF WORLD ACADEMY OF SCIENCE, ENGINEERING AND TECHNOLOGY, ISSN 2070-3740 ; 41
Keyword [en]
Compacted graphite iron (CGI), machinability, microstructure, milling, interlamellar distance in pearlite
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
SRA - Production
Identifiers
URN: urn:nbn:se:kth:diva-28205OAI: oai:DiVA.org:kth-28205DiVA: diva2:385151
Funder
XPRES - Initiative for excellence in production research
Note
QC 20110112Available from: 2011-01-11 Created: 2011-01-11 Last updated: 2011-11-21Bibliographically approved
In thesis
1. Criteria for Machinability Evaluation of Compacted Graphite Iron Materials: Design and Production Planning Perspective on Cylinder Block Manufacturing
Open this publication in new window or tab >>Criteria for Machinability Evaluation of Compacted Graphite Iron Materials: Design and Production Planning Perspective on Cylinder Block Manufacturing
2011 (English)Doctoral thesis, comprehensive summary (Other academic)
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.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2011. xiii, 75 p.
Series
TRITA-IIP, ISSN 1650-1888 ; 2011-10
Keyword
Metal Cutting, Compacted Graphite Iron (CGI), Machinability, Design of Experiments (DoE), Inverse Finite Element (FE) Modelling, Simulated Milling Method
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
SRA - Production
Identifiers
urn:nbn:se:kth:diva-48430 (URN)978-91-7501-159-2 (ISBN)
Public defence
2011-12-02, F3, Lindstedtsväg 26, KTH, Stockholm, 09:00 (English)
Opponent
Supervisors
Projects
MERA - OPTIMA CGIFFI - OPTIMA phase two
Funder
XPRES - Initiative for excellence in production research
Note

QC 20111121

Available from: 2011-11-21 Created: 2011-11-18 Last updated: 2017-05-23Bibliographically approved

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