Machined surface of fcd 700 ductile cast iron in a dry turning environment using carbide tools

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Abstract

Machining is one of the most important processes in producing automotive components such as difficult to cut cast iron grade FCD700. Trying to improve the machining technique, for the benefit of humanity and the environment, is a continuous process. This paper presents an environmentally-friendly method of turning FCD700 cast iron using a carbide tool without coolant. The turning process was carried out in three types of dry conditions, i.e. without air, in chilled air and in normal air. The turning parameters studied were cutting speed (100-300 m/min), feed rate (0.1-0.4 mm/rev), and depth of cut (0.2-2.0 mm). Results show that the average surface roughness (Ra) was greatly affected by the feed rate, while the effect of depth of cut was negligible. A low Ra value was produced at a high cutting speed, especially at a medium air temperature of 10 deg C. The Ra obtained deteriorated with cooler chilled air at -2 deg C, when compared to cutting in an environment without air. A high feed rate produced a coarser surface finish at the beginning of the cut, but as the tools wore out the machined surface topography remained similar, regardless of the value of the feed rate used.

Original languageEnglish
Pages (from-to)362-366
Number of pages5
JournalInternational Journal of Mechanical and Materials Engineering
Volume6
Issue number3
Publication statusPublished - Dec 2011

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Carbide tools
Cast iron
Air
Machining
Surface topography
Coolants
Surface roughness
Wear of materials

Keywords

  • Carbide tool
  • Dry turning
  • FCD700 cast iron
  • Surface roughness
  • Surface topography

ASJC Scopus subject areas

  • Mechanical Engineering
  • Mechanics of Materials
  • Materials Science(all)

Cite this

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title = "Machined surface of fcd 700 ductile cast iron in a dry turning environment using carbide tools",
abstract = "Machining is one of the most important processes in producing automotive components such as difficult to cut cast iron grade FCD700. Trying to improve the machining technique, for the benefit of humanity and the environment, is a continuous process. This paper presents an environmentally-friendly method of turning FCD700 cast iron using a carbide tool without coolant. The turning process was carried out in three types of dry conditions, i.e. without air, in chilled air and in normal air. The turning parameters studied were cutting speed (100-300 m/min), feed rate (0.1-0.4 mm/rev), and depth of cut (0.2-2.0 mm). Results show that the average surface roughness (Ra) was greatly affected by the feed rate, while the effect of depth of cut was negligible. A low Ra value was produced at a high cutting speed, especially at a medium air temperature of 10 deg C. The Ra obtained deteriorated with cooler chilled air at -2 deg C, when compared to cutting in an environment without air. A high feed rate produced a coarser surface finish at the beginning of the cut, but as the tools wore out the machined surface topography remained similar, regardless of the value of the feed rate used.",
keywords = "Carbide tool, Dry turning, FCD700 cast iron, Surface roughness, Surface topography",
author = "{A Ghani}, Jaharah and K. Othman and {Ab Rahman}, {Mohd Nizam} and {Md Deros}, Baba and {Che Haron}, {Che Hassan}",
year = "2011",
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AU - Che Haron, Che Hassan

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N2 - Machining is one of the most important processes in producing automotive components such as difficult to cut cast iron grade FCD700. Trying to improve the machining technique, for the benefit of humanity and the environment, is a continuous process. This paper presents an environmentally-friendly method of turning FCD700 cast iron using a carbide tool without coolant. The turning process was carried out in three types of dry conditions, i.e. without air, in chilled air and in normal air. The turning parameters studied were cutting speed (100-300 m/min), feed rate (0.1-0.4 mm/rev), and depth of cut (0.2-2.0 mm). Results show that the average surface roughness (Ra) was greatly affected by the feed rate, while the effect of depth of cut was negligible. A low Ra value was produced at a high cutting speed, especially at a medium air temperature of 10 deg C. The Ra obtained deteriorated with cooler chilled air at -2 deg C, when compared to cutting in an environment without air. A high feed rate produced a coarser surface finish at the beginning of the cut, but as the tools wore out the machined surface topography remained similar, regardless of the value of the feed rate used.

AB - Machining is one of the most important processes in producing automotive components such as difficult to cut cast iron grade FCD700. Trying to improve the machining technique, for the benefit of humanity and the environment, is a continuous process. This paper presents an environmentally-friendly method of turning FCD700 cast iron using a carbide tool without coolant. The turning process was carried out in three types of dry conditions, i.e. without air, in chilled air and in normal air. The turning parameters studied were cutting speed (100-300 m/min), feed rate (0.1-0.4 mm/rev), and depth of cut (0.2-2.0 mm). Results show that the average surface roughness (Ra) was greatly affected by the feed rate, while the effect of depth of cut was negligible. A low Ra value was produced at a high cutting speed, especially at a medium air temperature of 10 deg C. The Ra obtained deteriorated with cooler chilled air at -2 deg C, when compared to cutting in an environment without air. A high feed rate produced a coarser surface finish at the beginning of the cut, but as the tools wore out the machined surface topography remained similar, regardless of the value of the feed rate used.

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