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A Study of tool wear behaviour during milling of Compacted Graphite Iron under dry and minimum quantity lubrication conditions

Monroe Diaz, Kevin LU (2022) MMTM05 20221
Production and Materials Engineering
Abstract
The search for stronger materials in the automotive industry resulted in an increased used of Compacted graphite iron (CGI) instead of gray cast iron; however, the machinability of this material is more difficult, and different approaches such as composition modification, improved tooling and improved cutting conditions have been attempted.
This thesis project is focused on the analysis of tool wear when milling CGI while testing three different conditions. First, the assessment of a relatively new environmentally friendly lubrication option such as Minimum quantity lubricant (MQL) using rapeseed oil as the lubricant. Second, the analysis of the tool wear mechanisms present when the cutting speed and feed are modified. Last, the study of... (More)
The search for stronger materials in the automotive industry resulted in an increased used of Compacted graphite iron (CGI) instead of gray cast iron; however, the machinability of this material is more difficult, and different approaches such as composition modification, improved tooling and improved cutting conditions have been attempted.
This thesis project is focused on the analysis of tool wear when milling CGI while testing three different conditions. First, the assessment of a relatively new environmentally friendly lubrication option such as Minimum quantity lubricant (MQL) using rapeseed oil as the lubricant. Second, the analysis of the tool wear mechanisms present when the cutting speed and feed are modified. Last, the study of the influence in tool wear of CGI aging.
The results showed that MQL has a positive effect on milling, causing a 14-18% reduction of flank wear (VB) compared to dry machining, using a tool wear criterion of 200 µm. Additionally, adding graphite nano particles (GnP) to the oil didn’t have a positive effect on tool wear. For the second focus of study, while abrasion was present in all cutting speeds, adhesion was very noticeable at lower speeds, while diffusion and crater wear were more common at the higher speeds due to increased temperatures. Regarding aging, results showed less tool cratering after milling CGI aged for a year compared to others reset and aged for 4 and 11 days; nevertheless, more cutting speeds would be required to make a more robust statement on the effect of aging. (Less)
Please use this url to cite or link to this publication:
author
Monroe Diaz, Kevin LU
supervisor
organization
course
MMTM05 20221
year
type
H2 - Master's Degree (Two Years)
subject
keywords
Compacted Graphite Iron, Minimum Quantity Lubrication, CVD, PVD, Tool wear, Machinability
report number
LUTMDN/(TMMV-5335)/1-107/2022
language
English
id
9089454
date added to LUP
2022-06-16 13:50:51
date last changed
2022-06-16 13:50:51
@misc{9089454,
  abstract     = {{The search for stronger materials in the automotive industry resulted in an increased used of Compacted graphite iron (CGI) instead of gray cast iron; however, the machinability of this material is more difficult, and different approaches such as composition modification, improved tooling and improved cutting conditions have been attempted.
	This thesis project is focused on the analysis of tool wear when milling CGI while testing three different conditions. First, the assessment of a relatively new environmentally friendly lubrication option such as Minimum quantity lubricant (MQL) using rapeseed oil as the lubricant. Second, the analysis of the tool wear mechanisms present when the cutting speed and feed are modified. Last, the study of the influence in tool wear of CGI aging.
	The results showed that MQL has a positive effect on milling, causing a 14-18% reduction of flank wear (VB) compared to dry machining, using a tool wear criterion of 200 µm. Additionally, adding graphite nano particles (GnP) to the oil didn’t have a positive effect on tool wear. For the second focus of study, while abrasion was present in all cutting speeds, adhesion was very noticeable at lower speeds, while diffusion and crater wear were more common at the higher speeds due to increased temperatures. Regarding aging, results showed less tool cratering after milling CGI aged for a year compared to others reset and aged for 4 and 11 days; nevertheless, more cutting speeds would be required to make a more robust statement on the effect of aging.}},
  author       = {{Monroe Diaz, Kevin}},
  language     = {{eng}},
  note         = {{Student Paper}},
  title        = {{A Study of tool wear behaviour during milling of Compacted Graphite Iron under dry and minimum quantity lubrication conditions}},
  year         = {{2022}},
}