Machining of bi-metallic aluminium-grey cast iron engine block – process optimisation by means of FEM

Abstract

Bi-metallic design concept has been introduced in automotive industries to meet the increasingly tighter standards on carbon emission. Yet, machining of bi-metallic engine blocks is accompanied by several challenges like short tool life and long cycle times. This study presents a novel methodology that combines the concept of experimental design with Finite Element (FE) to optimise the tool performance and enhance the productivity when finish face milling of aluminium-grey cast iron engine blocks. This simulation-assisted approach led to an approximately 32% decrease in machining cycle time as compared to that of a reference cutting condition.