Effect of tool cutter immersion on Al-Si bi-metallic materials in High-Speed-Milling

• Autorzy: Sokołowski J. H. , Szablewski D. , Kasprzak W. , Ng E. G. , Dumitrescu M.
• Języki publikacji: EN

Abstrakty

EN

Purpose: Aluminum-Silicon (Al-Si) alloys are commonly used in the automotive industry. At high Si levels they offer good wear resistance. Abrasive wear however, has been identified as the main insert cutter damage mechanism during High-Speed-Milling (HSM). This study investigates the effect of the tool cutter immersion on Al-Si bi-metallic materials in HSM operation. Design/methodology/approach: This study considers the effects of the tool cutter immersion on the resultant cutting forces, associated machined surface roughness, and machined subsurface microstructural damage caused by the tool cutter during the Minimum Quantity Lubricant – High Speed Milling (MQL-HSM) operation of AlSi bi-metallic materials with varying amounts and morphologies of the silicon phase. Findings: Experimental results indicate that a combination of gray cast iron with the W319 microstructure yields the greatest resistance to the tool cutter rake face during the face milling operation for all investigated tool cutter radial immersions. Machined surface roughness measurements reveal that surface roughness is a function of both the silicon content and morphology, as well as the percentage of tool cutter immersion. Matrix hardness measurements indicate that machining at all immersions has the same effect on compressing the matrix structure. Research limitations/implications: This study considers the effects of the radial tooling immersion and material selection while the speed, feed, and axial depth-of-cut are kept constant. Future work should address variability in the machining parameters in an attempt to maximize tool life, while optimizing the machined surface quality. Practical implications: Material selection affects the machining conditions in HSM of Al-Si bi-metallic materials. As a result careful consideration should be given when tailoring the machining conditions to the cast microstructures. Originality/value: North American automakers rely heavily on Al-Si precision sand cast components. As a result bi-metallic machining has to be often addressed during the face milling of engine blocks and cylinder heads. The research conducted here broadens the understanding of the impact of radial immersion on the machining behavior of Al-Si bi-metallic materials.

Słowa kluczowe

EN

machining; Al-Si alloys; cutting forces; subsurface damage

PL

obróbka mechaniczna; stopy Al-Si; siły skrawania; uszkodzenia podpowierzchniowe

• Wydawca: International OCSCO World Press
• Czasopismo: Journal of Achievements in Materials and Manufacturing Engineering
• Rocznik: 2006
• Tom: Vol. 17, nr 1-2
• Strony: 15--20
• Opis fizyczny: Bibliogr. 13 poz., rys., tab., wykr.

Twórcy

autor

Sokołowski J. H.

• Mechanical, Automotive, Materials Engineering, University of Windsor, 401 Sunset Ave., N9B 3P4, Windsor, ON, Canada

autor

Szablewski D.

• Mechanical, Automotive, Materials Engineering, University of Windsor, 401 Sunset Ave., N9B 3P4, Windsor, ON, Canada
• Nemak of Canada Corporation, 4600 G.N. Booth Drive, N9C 4G8, Windsor, ON, Canada

autor

Kasprzak W.

• Mechanical, Automotive, Materials Engineering, University of Windsor, 401 Sunset Ave., N9B 3P4, Windsor, ON, Canada

autor

Ng E. G.

• Materials Manufacturing Research Institute, McMaster University, 1280 Main St. West, L8S 4L7, Hamilton, ON, Canada

autor

Dumitrescu M.

• Materials Manufacturing Research Institute, McMaster University, 1280 Main St. West, L8S 4L7, Hamilton, ON, Canada

Bibliografia

• [1] J.E. Gruzleski, B.M. Closset, The Treatment of Liquid Aluminum-Silicon Alloys, American Foudrymen’s Society Inc., 1990.
• [2] Information from http://www.Key-To-Metals.com, keyword: Aluminum-Silicon Alloys, August 27th, 2005.
• [3] H.A. Kishawy, M. Dumitrescu, E.G. Ng, M.A. Elbestawi, Effect of coolant strategy on tool performance, chip morphology, and surface quality during high-speed machining of A356 aluminum alloy, International Journal of Machine Tools & Manufacture, v. 45, 2005, p. 219-227.
• [4] M. Schultz, et al., Limits for the application of long protruding tools regarding the process stability and safety, Proceedings of the Second International Seminar on Improving Machine Tool Performance, La Baule, France, 2000.
• [5] L. Backerud, G. Chai, J. Tamminen, Solidification Characteristics of Aluminium Alloys, v. 1-3, 1990.
• [6] Lu Shu-Zu, A. Hellawell, The Mechanism of Silicon Modification in Aluminum-Silicon Alloys: Impurity Induced Twinning, Metallurgical Transactions, v. 18A, 1987, p. 1721-1733.
• [7] C.A. Queener, W.L. Mitchell, Effect of Iron Content and Sodium Modification on the Machinability of Aluminum Alloy Die Castings, AFS Transactions, v. 73, 1965, p. 14-19.
• [8] R. Sharan, N.P. Saksena, Rare Earth Additions As Modifiers of Aluminum Silicon Alloys, AFS International Cast Metals Journal, v. 3, 1987, p. 29-33.
• [9] N. Tenekedjiev, H. Mulazimoglu, B. Closset, J. Gruzleski, Microstructures and Thermal Analysis of Strontium-Treated Aluminum-Silicon Alloys, American Foundrymen’s Society Inc., 1995, p. 1-31.
• [10] J.H. Sokolowski, M.B. Djurdjevic, C.A. Kierkus, Northwood D.O., Improvement of 319 Aluminum Alloy Casting Durability by High Temperature Solution Treatment, Journal of Materials Processing Technology, v. 109, 2001, p. 174-180.
• [11] J.H. Sokolowski, X-C. Sun, G. Byczynski, D.O. Northwood, D.E. Penrod, R. Thomas, A. Esseltine, The Removal of Copper-Phase Segregation and the Subsequent Improvement in Mechanical Properties of Cast 319 Aluminum Alloys by a Two-Stage Solution Heat Treatment, Journal of Materials Processing Technology, vol. 53, 1995, p. 385-392.
• [12] Francisco Carlos Robles Hernandez, Improvement in Functional Characteristics of Al-Si Cast Components through the Utilization of a Novel Electromagnetic Treatment of Liquid Melts, Ph.D. Dissertation, 2004, University of Windsor.
• [13] Electromagnetic Method and Apparatus for Treatment of Engineering Materials, Products and Related Processes - IESV Technology Platform (US Provisional Patent Serial No. 60/431,236).