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UDK 621.9.0L:621.7.01 B. NEDELJKOVIC

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Correlation BetweenMachinability Index and Gray Iron Structural Parameters

Gray iron machinabitity is one of its most important characterisfics.A complex approach to the aim assumes respecfing of the direct inJluence of the casfing process to the machinability parameters of the castings.Basic parameters machinability is, before all, gray iron structure which dependson its chemical composition, melting condifions, modifcation, rctw material quality and otherfectors. The paper present research results between machinability and gray iron qualitatrve and quantitafive microstructure parometers. Keywords:machinability, gray iron, microstructure, casting

1. INTRODUCTION Gray iron machinability, as one of more important gray characteristics,has always been watched from the aspect of cutting control, cutting speed, cutting blade structure, type of hard coating and other technological factors and very rarely, or almost never, from the aspects of structure and material is, in fact, the basic point of this paper. characteristics Highly productive automatic transfer machines for castings,as it is the casewith breaking drums, at high cutting speeds require constant cutting resistances and any variation representsa serious problem at the target aim of largecastrngseries.For that reason, this paper \\'as to promote casting technology in the function of machinability casting advancement.

All the charge conditioning and alloying materials were pre-analyzedand were added to the charge in the furnace. After the first batch of castings,was poured,the melt underwentchemical analysis on a Philips PV 8300 emissionspectrometer. Previously modified liquid metal, prepared in this w&y, was cast into moulds with a 0.1% SiCa based inoculant. The first cast was followed by batch correctioninside the induction furnace and chemical analysisrepeated. Table I shows the results of chemical composition tests. of liquid metal Table I. Chemicalcomposition Content No Element First batch batch Second

2. RESEARCH PROGRAMME The preparation and casting of the test batcheswas carried out in four ton induction furnaces,using the following chargemake up: . o . steelmotor car body sheetpackedin bales, returned grey iron (scrap castings, runners and risers), carburisingand alloying agents.

I 2. 3.
4.

Carbon
Silicon Manganese Boron

3.00 1.80 0.50 0.076 0.045 0.042 0.030

310
L90

085 0.032 0.054 0.060 0 028

5 6. 7.

Phosphorus Sulphur Aluminium

Dr B. Nedeljkovii, "Zastava automobili" Centralni laboratoii um Kragujevac

Before castrnginto the moulds,the liquid metal from the second batchwas alsomodifiedwith 0.1%SiCa.

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Tribolog,,inindustry,Volume 22, No. I&2,2000.

2.2. Drum machinability tests Fl, F2 and F3 were measured Cuttrng resistances as the parameters to define the machinability index without the applicationof a cooling agent. Operations on the test sampleswere carriedout on a universal lathe using accepted computer supported regimes:

Chemical compositionof liquid metal CoromantSNMA: 120412Sandvikplate, Numberof revolutions: n:560rpm Pitch:S:0.llZmmlr Cutting depth:d:0.3mm

3. MEASURING INSTRUMENTS A dynamometer,connectedto the tool carner vicr tensiometrically resistant feeds, passing the signal through a measuring bridge to amplifier and a recorder(figure l) was used to measureFl, F2 and F3 cutting resistances and machinabilityindex.

4. MIKROSTRUCTURE TEASTING Metallographic tests were carried out on samples obtainedby cutting piecesfrom a ring shapedpart of the drum which had had its machinability monitored: characteristics r . qualitativemicrostructure tests microstructure assay.

Figure L Three componentdynamometer

Qualitative microstructure tests were performed accordingto DIN/6911964 for: standard o o

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metal basemicrostructure graphite shape,arrangement and size.

! 2t )) lJ 21 2J 20 nurnber 2; 2E 29 Ju

Quantitative microstructure tests were carried fbr graphiteplatesrepresentative samples, obtainedtiom all threebatches.
Dmm

. r . r

graphiteplates surfaceAa, m m2 perimeter(circumference) La, m m gap betweengraphite plates Lo,nm m graphiteplateswidth Lg,., rn rn.

x
! ;a.
a!

! E
{l

Other values important for cast microstructure quality assessment were calculated on the basisof the above-mentioned measurement of physicalvalues.

5. RESULTS OF TESTING procedure for The establishing material machinability characteristics by measuriug corresponding cutting resistance is based components on the differencesthat exist in the formula Fl:f(T) for the different seriesof machiningtestswhen other machiningconditionsare kept constant. Because of limited space,only the meanvaluesof the machinability index for both passes of the nrain (Fl) for all three batches cutting resistance are shown (figure 2).

x c)
h

z,

Figure 2. Mean values of machinability indexfor series | (top), series 2 (middle) and series 3 (bottom)

Tribolog,,in indust4y,Volum e 22, No. 1&2r 2000.

ll

Table 2. Structural graphite parameters of grey iron

No Samp les1 charg Distance between graphite plate Losn (pm) Aa (um)
mln

LA

max

sr
/.-1J

nlln

1pm)2 max
-1J I

sr 19.53
J /U

Graphite plate width [GR) ((um) sr mln max

Rnr N/m 1 m

HB

N.x l0-3 pnl

Sv pm/ 3 nl

41ll 23I1 3
A

0.5 8 1.43 1.35 t.2l 1.43

I t.o

13.9 24.9

0.29
0.39 0.'17 0.05 0.61

225
434 295 257

2.54 5.1 3.6 0.27 5.13

0 .l 6 0.25

4.0 4.75 5.4

0.96 t.4 1.5 1.5

195.3 290.1 284.5 346.3 366.6

150.3 207

9.07 3.48
3.+>

24.8
A1 1

t'12

r9.8
I9.8

362 428 280 2'll

29m rT{trl
l9lIU

202
150.3 153

24
16.6

34.9 26.8 28.6

0.20
0.01 0.07

208

++.JZ

tz.4
12.8

3.6
4.08

22s
227

4.91 5.68

34.04
JO.-)

2t.6

r82

r.27

6. QUANTITATIVE METALLOGRAPHIC TESTS Table 2 shows the results of measuredvalues that quantitatively define the microstructure of the castingstested. Figs 3-7 show correlation between the measured parameters of castings microstructure and samplesfrom machinability index for representative all thrce batches

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-fi 9

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-=#
i

I
0.6 ^ .A . * nt

: 'o o .= .c.
9

;
T
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.'----

T'
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-'-l_

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',l 1l 13 5 t7 Plote surfoce, Ao [pm']

19

machinabilityindex Figure 5. Correlationbetween and the distancebetween grophite plates

1 I
*i
, . } -

ii:ii
t r I I I

-o x 0) .c

0.8 0.6
u.e

o .C .c.

8 o.2
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!1620242t

The distance beh.veen graphite plates L. [pm ]

30 34 38 42 26 Surfoce densfi, S, [pm'/pm']

46

Figure 3. Correlation betweenmachinability index and plate surfbce

Figure 6. Correlafion betweenmachinability index dependence of graphite plate width

..:>a o D .c
.C .C O o

0.6 0.4
aa v1

5 7 9 6 I Numenkol density, N. xl0'[pm'l

r0

Figure 1. Correlattonbetweenmochinobilityindex and surface

Figure 7. Machinability index dependence on numericoldensitv

t2

in industry,Volume 22, No. l&2,2000. TribologS,,

7. CONCLUSION o Obtainedresultspoint out the existenceof non unified machinability of tested drums within the samecharge. It is observed that value machinability index at the third charge is slightly worse than at the second one regardlessof increasedmechanical properties (Rm and HB results are not presented in this paper). This is the consequence of better inoculation of liquid metal of the third charge relativeto the secondone. With the increase of numericdensityNo, surface of lamella Ae surface density Sv and width of graphite lamellas LcR, also the machinability index is increased if metal baseis the same. Significantly bigger index of machinability of castings from the first charge relative to the second and the third charee is the result of

presence of larger shareof fenite in metal base.

REFERENCES |.lfrlfunovic D., Master of Degree paperwork Energetic aspectof machinability by scraping of gray iron with multiple coated cutting tools made of hard metal, Kragujevac1991. Nedeljkovic 8., Milit //. . 12.lBabic M., Modertitation of machinability and tribological properties of casting from gray iron, study on project realization 1.3.0668, Kragujevac1994. [3.]NedeljkovicB, Ph. D. thesis, Effect of micro structure on machinability of gray iron, Beograd1995.

Tribologtin industry, Volume 22, No. 1&2, 2000.

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