An experimental investigation into the machinability of GGG-70 grade spheroidal graphite cast iron

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1 Indian Journal of Engineering & Materials Sciences Vol. 16, April 2009, pp An experimental investigation into the machinability of GGG-70 grade spheroidal graphite cast iron Ihsan Korkut a *, Kadir Yavuz b & Yakup Turgut a a Technical Education Faculty, Gazi University, 06500, Besevler, Ankara, Turkey b Ataturk A.T.L. A.M.L. and Industry Career High-School, Sivas, Turkey Received 22 July 2008; accepted 16 March 2009 In this study, machining tests of the bearing necks of crank shafts produced from GGG-70 grade ductile iron (DI) are carried out. Coated cemented carbide inserts are used in the machining tests. The tests are carried out at four different cutting speeds (250, 275, 300 and 325 m/min), three different feed rates (0.15, 0.25 and 0.30 mm/rev) and two different depth (0.5 mm and 2 mm). The effects of these parameters on the surface roughness and the cutting force are investigated. Increasing cutting speed is found to deteriorate the surface roughness. The best average surface roughness values are obtained at 250 m/min which is the lowest cutting speed. Main cutting forces increased with increasing feed rate and depth of cut. Keywords: Ductile iron (DI), Cam shaft, Machinability, Cutting forces, Surface roughness Crank shafts are usually made from ductile iron (DI). Cost of crank and crank shafts made from DI is about 30% lower than those made from forged steel 1-4. Strength, ductility and toughness of ductile iron are better than those of flake graphite cast iron. This is the result of spheroidal graphite morphology in the structure of ductile iron. Due to its enhanced properties over flake graphite cast iron, ductile iron is used where high strength and wear resistance are required. Machine parts, pipe, and crankshafts are typical industrial applications of ductile iron 5,6. However, comparing with graphite flake and malleable cast irons, the machinability of ductile iron is poor because of its enhanced mechanical property 7. In ductile iron, the graphite spheres are less effective than the flake graphite in weakening the material in the shear plane, and the flow zone material may sometimes be extremely ductile 8. The aim of this study is to carry out machining tests on bearing necks of crank shafts produced from GGG-70 grade ductile iron used in automotive industry. This paper concentrates on the influences of cutting tool geometries, cutting speed, feed rate and depth of cut on surface roughness and cutting forces. Materials and Methods For machining tests, GGG-70 grade ductile iron *For correspondence ( ikorkut@gazi.edu.tr) crank shafts were used as the workpiece materials. Chemical composition of the workpiece materials is given in Table 1. The chemical composition analysis of this material was carried out using an OBLF- Spektrometer device. Sections were cut out of the workpiece materials to carry out microstructural examinations and hardness analysis. These sections were hot mounted in Bakelite and then ground using SiC papers. After polishing the sections using diamond paste, they were etched in 2% nital solution (Fig. 1). Figure 1 shows microstructure photographs that were taken at various magnifications from these etched specimens using an optical microscope. Hardness values of the workpiece specimen was determined as 262 HB using an Instron Wolpert hardness measuring unit employing a 10 mm diameter ball under 3000 kg load. Machining tests were carried out in accordance with ISO 3685 on a Johnford TC35 CNC turning centre, with a variable spindle speed of up to 4000 rpm and a power rating of 10 kw. The cutting parameters used are given in Table 2. The turning tests were carried out using coated cemented carbide cutting tool with negative and positive geometries. A total of 48 tests were carried out. The cutting tools used were commercial grade inserts produced by Sandvik Coromant with the geometries of DNMG KM and DCMT

2 KORKUT et al.: MACHINABILITY OF GGG-70 GRADE SPHEROIDAL GRAPHITE CAST IRON 117 Table 1 Chemical composition of GGG-70 ductile iron (% weight) C 3.57 S Cu V Sb <0.001 Si 2.05 Cr Al W <0.003 Mg Mn Ni Co <0.001 Pb <0.001 Fe Balance P Mo <0.001 Ti Sn Table 2 Cutting parameters used for the tests Cutting conditions I II III IV Cutting speed (m/min) Feed rate (mm/rev) Depth of cut (mm) Tool geometry Negative, Positive 11T308-KM. These inserts had GC 3210 Sandvik designation which is equivalent to K10 according to ISO and recommended for machining ductile irons. These inserts were clamped mechanically on a rigid tool holder. Surface roughness measurement was carried out on the machined surfaces using a Mahr Perthometer M1 instrument. Cutting force was measured with a Kistler 9257A three component piezoelectric dynamometer and associated 5019 B130 charge amplifiers connected to a PC employing Kistler Dynoware force measurement software. Results and Discussion Fig. 1 Microstructure of GGG-70 grade ductile iron used for the machining tests (a) magnification: 100 and (b) magnification: 200; (etched: 2% nital) Fig. 2 Variation of chip cross-section depending on depth of cut and feed rate (a) a=2 mm, f=0.3 mm/rev and (b) a=0.5 mm, f=0.3 mm/rev Evaluation of cutting forces Depending on the cutting tool tip radius, radial force (F r ) and feed force (F f ) components show variations. This is also same for the depth lower than the cutting tool tip radius. Increasing depth of cuts increases radial cutting force components. Radial force components lead to the deflection of workpiece and cutting tool and affect the rigidity negatively. The tip radii of cutting tools used for the machining tests were 0.8 mm. For the tests carried out at 0.5 mm depth of cut, a depth of cut lower than the tool tip radius was the case. This results in tapering of the chip and affects the chip flow directions. Cutting tool tip radius also determines the minimum depth of cut. When depth of cut was lower than the tool tip radius, the cutting tool tries to push away workpiece rather than cutting and hardens the workpiece surface. This, in turn, results in greater deformation. As the process continues, the chip accumulates ahead of the cutting tool and chatter takes place. This also results in a hardened and burnished surface. When the depth of cut was 2 mm for the tests, feed forces obtained were larger than radial forces. However, when the depth of cut was 0.5 mm, radial forces obtained were larger than the feed forces. This was the same for the both tool geometries. Figure 2 shows the variation of chip cross-section when cutting at 2 and 0.5 mm depth and 0.3 mm/rev feed rate 9.

3 118 INDIAN J. ENG. MATER. SCI., APRIL 2009 At a depth of cut lower than the cutting tool tip radius, the cutting tool acts as a round shaped insert and tool-workpiece contact length in radial direction becomes larger when compared to feed direction. Therefore, radial force becomes larger than the feed force. This larger radial force can be attributed to lower depth of cut. Chip cross-sectional area increases with increasing depth of cut and feed rate. In this study, all the three components of the cutting force increased significantly with increasing chip cross-sectional area. This situation is in agreement with the literature. As can be seen from Fig. 3a, main cutting force shows a decreasing trend with increasing cutting speed from 250 m/min up to 300 m/min, however, further increase in cutting speed from 300 m/min to 325 m/min leads to an increasing trend of primary cutting force. This situation is the same for all the three feed rates. Low cutting speed decreases chip curl radius and increases chip thickness. Larger chip thickness decreases the shear plane angle and this, in turn, requires larger forces and stresses to deform the material in the cutting zone. As the result of larger forces and stresses, vibration and heat also increase. Further increase in cutting speed beyond 300 m/min also increased the primary cutting force. This situation indicates that 325 m/min cutting speed is high for the cutting tool and workpiece materials and the cutting tool wears rapidly at this cutting speed. Figure 3b shows that main cutting forces increase with increasing cutting speed from 250 m/min up to 300 m/min. However, further increase of cutting speed to 325 m/min leads to a decrease in main cutting forces. This situation is the same for all the three feed rates. The variation in main cutting forces is opposite of that in Fig. 3a. In Fig. 3b, the lowest main cutting forces are observed at 250 m/min. It can be said that 0.5 mm depth of cut is not suitable for the cutting tool tip radius and this can be a reason for this reverse trend. Rake angle (γ) has significant influence on both main cutting force and radial cutting force perpendicular to the main cutting force. Negative cutting tools with - 6 rake angle produced greater cutting forces than the cutting tools with 0 rake angle. In the literature, resultant force increases with changing rake angles from negative to positive. The similar results were obtained from the tests. This can be seen from Figs 3 and 4. Fig. 3 Main cutting forces (F c ) obtained when machining with negative cutting tool against cutting speed at (a) 2 mm and (b) 0.5 mm depth Fig. 4 Main cutting forces (F c ) obtained when machining with positive cutting tool against cutting speed at (a) 2 mm and (b) 0.5 mm depth

4 KORKUT et al.: MACHINABILITY OF GGG-70 GRADE SPHEROIDAL GRAPHITE CAST IRON 119 Approach angles (λ) of the negative and positive cutting tools used for the machining tests were - 7 and 0, respectively. Approach angle directly influences chip flow direction. When approach angle is positive, chip flows towards the cutting tool. However, when it is negative, chip flows towards the workpiece and a decrease in cutting edge length is observed. In this case, tool edge can also shift below the workpiece axis. Negative approach angle increases cutting edge strength but in this case the tool encounters difficulty in penetrating the workpiece. It is seen from Fig. 4a that main cutting forces increase when cutting speed is raised to 275 m/min from 250 m/min and then decrease when cutting speed is increased to 300 m/min and finally increase again when cutting speed is increased to 325 m/min. Main cutting forces exhibit a fluctuating trend for all the feed rates. The lowest cutting forces with positive cutting tool were also obtained at 300 m/min cutting speed as in the case of negative cutting tool. Therefore, it can be said that 300 m/min is the optimum cutting speed in terms of main cutting force for the both cutting tool geometries at 2 m/min depth of cut. In Fig. 4b, it is seen that main cutting forces decrease with increasing cutting speed for the three feed rates at 0.5 mm depth of cut. Positive cutting tool geometry eliminates the risk of BUE formation. 0 inclination angle of positive cutting tool decreases the radial cutting forces and the constant relief angle around the cutting tool nose radius with strong cutting edge form. This cutting tool geometry is suitable for machining long and thin parts sensitive to vibration and also suitable for general turning applications where the cutting conditions vary. Positive geometry provides low cutting forces. When positive and negative rake angles are compared, negative rake angle increases cutting forces while it decreases loads on machined surfaces. It should be noted that cutting tool nose radii of more than 0.8 mm allow higher feed rates and if there is vibration tendency, smaller nose radii should be selected. Vibration tendency is a result of cutting forces. Vibration cannot only stem from deflections of cutting tools and workpiece but also variations in cutting and material conditions can result in vibration. BUE formation also leads to variations in cutting forces and to vibrations. Importance of chip formation geometry, providing suitable chip break, using a cutting tool of positive rake angle and selection of high cutting speed have all positive influence on cutting forces. It is seen from the curves in Figs 5 and 6 that increasing feed rates and depth of cut increases main cutting forces. This increase is seen for the both tool geometries used in the tests. Chip cross-sectional area product of feed rate and depth of cut is the most important factor in determining main cutting force. Figures 5 and 6 show that main cutting force increases as depth of cut and feed rate increase. Increasing chip cross-sectional area with increasing feed rate and depth cut is the reason for this increase. Evaluation of surface roughness Surface roughness measurements were made three times at different places on the machined surfaces after machining with each tool and the averages of these three measurements were taken. Figures 7-10 give the surface roughness measurement results. When Figs 7 and 8 are examined, variations of average surface roughness values depending on 0.15 mm/rev, 0.25 mm/rev and 0.30 mm/rev of feed rates at different cutting speeds are seen. When cutting speed is increased, average surface roughness values Fig. 5 Main cutting forces (F c ) obtained when machining with negative cutting tool against feed rate at (a) 2 mm and (b) 0.5 mm depth

5 120 INDIAN J. ENG. MATER. SCI., APRIL 2009 Fig. 6 Main cutting forces (F c ) obtained when machining with positive cutting tool against feed rate at (a) 2 mm and (b) 0.5 mm depth Fig. 7 Surface roughness (R a ) obtained by machining with negative cutting tool against cutting speed at (a) 2 mm and (b) 0.5 mm depth Fig. 8 Surface roughness (R a ) obtained by machining with positive cutting tool against cutting speed at (a) 2 mm and (b) 0.5 mm depth Fig. 9 Surface roughness (R a ) obtained by machining with negative cutting tool against feed rate at (a) 2 mm and (b) 0.5 mm depth of cuts

6 KORKUT et al.: MACHINABILITY OF GGG-70 GRADE SPHEROIDAL GRAPHITE CAST IRON 121 Fig. 10 Surface roughness (R a ) obtained by machining with positive cutting tool against feed rate at (a) 2 mm and (b) 0.5 mm depth of cuts also increase. Differently, average surface roughness initially decreases with increasing cutting speed and then increases with further increase in cutting speed when machining with negative cutting tool at 0.5 mm depth of cut and 300 m/min cutting speed. Increasing surface roughness with increasing cutting speed is in disagreement with literature. However, quite long workpiece was considered to lead to excessive vibration and deflections. As the result of vibration and deflections, chatter causing a poor surface quality occurs. In order to prevent this, workpiece should be supported suitably during machining. The lowest average surface roughness values were obtained from the tests carried out at the lowest cutting speed (250 m/min). While the average surface roughness values were low at 250 m/min cutting speed, it was seen that average surface roughness values was affected negatively with increasing cutting speed. Variations of average surface roughness values depending on feed rate at 250, 275, 300 and 325 m/min cutting speeds are given in Figs 9 and 10 with curves. It is seen from these curves that increasing feed rate increased the surface roughness values at all the cutting speeds. It is seen from the curves that surface roughness increase is more obvious when the feed rate is increased from 0.15 mm/rev to 0.25 mm/rev. This increase in surface roughness with increasing feed rate is in agreement with the reported studies 10. If the curves in Figs 9 and 10 are examined by taking into consideration surface roughness depending on depth of cut, it is seen that surfaces obtained with negative cutting tool at 0.15 mm/rev feed rate and 0.5 mm depth of cut are better than those obtained at 2 mm depth of cut at the same feed rate. However, 2 mm depth of cut results in better surfaces than 0.5 mm depth of cut when positive cutting tool is used. Conclusions The following conclusions can be drawn from the present study: Chip cross-sectional area which is the product of feed rate and depth of cut is the most important factor affecting cutting forces. With increasing feed rate, main cutting forces for the both tool geometries increased. When the depth of cut 2 mm, the lowest cutting force for the both tool geometries was obtained at 300 m/min cutting speed. When the cutting speed was increased, only machining with positive cutting tool at 0.5 depth of cut showed a continuous decrease in cutting forces. It was determined that feed rate was the most important factor on surface roughness. At all the cutting speeds for the both tool geometries, increasing feed rate increase the average surface roughness. When feed rate was increased from 0.15 mm/rev to 0.25 mm/rev, the obtained surface roughness values increased by 100%. Similarly, 300% increase in surface roughness values were observed when feed rate was increased from 0.15 mm/rev to 0.30 mm/rev. Increase in cutting speed deteriorates the surface roughness, the best average surface roughness values were obtained at 250 m/min which was the lowest cutting speed. Apart from 0.15 mm/rev feed rate, the depth of cut did not have any meaningful effect on average surface roughness. The factors having effect on surface roughness were determined in order of importance as follows: feed rate, cutting speed and depth of cut. Acknowledgement The authors would like to acknowledge Gazi

7 122 INDIAN J. ENG. MATER. SCI., APRIL 2009 University Scientific Research Projects (41/ ) for the financial support. References 1 Lin S C, Lui T S, Chen L H & Song J M, Metall Mater Trans, 33(A) (2002) Lessiter M J, Engineered cast components for the automotive industry, Engineered Casting Solutions, Fall, (2000) Bosnjak B, Radulovic B, Pop-Tonev K & Asanoviv V, J Mater Eng Perform, 10(2) (2001) Thomas T R, Rough surface (Longman Group Limited, London and New York), 1982, Groover M P, Fundamentals of modern manufacturingmaterials process and systems, (Prentice-Hall), 1996, Kalpakjian S, Manufacturing process for engineering materials, 2nd ed. (Edison-Wesley), 1991, Seker U & Hasirci H, J Mater Process Technol, 173 (2006) Trent E M, Metal cutting (London, Tanner Ltd), 1984, Yavuz K, An experimental investigation into the machinability of GGG-70 grade spheroidal graphite cast iron cam shafts, M.Sc. Thesis, Gazi University Institute of Science and Technology, Ankara, Turkey, (2006). 10 Yan B H, Huang F Y & Chow H M, J Mater Process Technol, 54 (1995)

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