Abstract
Compacted Graphite Iron, (CGI) is known to have outstanding mechanical strength and weight-to-strength ratio as compared to conventional grey cast iron, (CI). The outstanding characteristics of CGI is due to its graphite particle shape, which is presented as compacted vermicular particle. The graphite is interconnected with random orientation and round edges, which results in higher mechanical strength. Whereas, graphite in the CI consists of a smooth-surfaced flakes that easily propagates cracks which results in weaker and brittle properties as compared to CGI. Owing to its improved properties, CGI is considered as the best candidate material in substituting grey cast iron that has been used in engine block applications for years. However, the smooth implementation of replacing CI with CGI has been hindered due to the poor machinability of CGI especially at high cutting speed. The tool life is decreased by 20 times when comparing CGI with CI under the same cutting condition. This study investigates the effect of using cryogenic cooling and minimum quantity lubrication (MQL) during high-speed milling of CGI (grade 450). Results showed that, the combination of internal cryogenic cooling and enhanced MQL improved the tool life, cutting force and surface quality as compared to the conventional flood coolant strategy during high-speed milling of CGI.
Highlights
Grey Cast Iron (CI) has been widely used in the manufacturing of engine blocks and cylinder heads for so many years due to its mechanical and physical properties
This study investigated the effectiveness of minimum quantity lubrication (MQL) with added nano-particle using MQL with added Hexagonal Boron Nitride (hBN) nano-particle when machining Compacted Graphite Iron (CGI)
The energy dispersive X-ray spectroscopy (EDX) spectra reveals that, the tool material for with conventional flood coolant (WET) strategy exhibits a strong adhesion of workpiece material
Summary
Grey Cast Iron (CI) has been widely used in the manufacturing of engine blocks and cylinder heads for so many years due to its mechanical and physical properties. The repetition of start-up and shutdown of engines can cause high mechanical loading and may lead to localized crack at the engine blocks and heads as a result of thermo-mechanical fatigue [1, 2]. From this aspect, researchers have found that Compacted Graphite Iron (CGI) is the best candidate in replacing CI. Owing to the improved properties, CGI is considered a suitable candidate to substitute the grey cast iron in various components for diesel engine; such as engine blocks, cylinder heads and cylinder sleeves [4]
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