Abstract
Gray cast iron (GCI) is highly anisotropic at the microscale consisting of stochastically distributed and orientated graphite flakes within a ferric matrix. The anisotropy of the microstructure endows gray cast iron with favorable damping characteristics which makes it a common material for machine tool structural components. However, the microstructure inhibits the formation of a finished surface of sufficient quality for use as a slideway when milled with a defined cutting edge. The mechanisms of irregular surface formation during the machining of GCI were investigated using both a 3-D finite element cutting simulation and milling experiments. Investigation of simulation and machining tests indicates that the interaction of the primary shear zone in front of the cutting edge and graphite flakes is the cause of microcavity formation on the machined surface.
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