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Research on different cooling methods in the machining of CGI and GCI

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Abstract

Gray cast iron (GCI) is the most common material used in diesel engine blocks. Compacted graphite iron (CGI) is a new material for high-power diesel engine blocks, which can allow an increase in the cylinder-pressures and achieve better fuel economy and a higher power output. However, the difficult machinability of CGI seriously hinders its large scale production. At high-speed machining, the tool life of machining GCI is 10–20 times that of GCI. To improve the tool life of machining CGI, this work focuses on the influence of uncooled, cutting fluid cooled and liquid nitrogen (LN2) cooled methods in the machining of CGI and GCI. The results indicate that LN2 cooled method can effectively reduce the highest temperature and temperature diffusion in the processing. Furthermore, for machining CGI, LN2 cooled method increases the tool life by 192.6% and 66.7% compared with uncooled and cutting fluid cooled methods, respectively. However, for machining GCI, LN2 cooled method plays a negative role. For CGI and GCI, the wear modes of the tools are similar, which are mainly material adhesion, coating wear and adhesion and built-up edge.

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Abbreviations

CGI:

Compacted graphite iron

GCI:

Gray cast iron

LN2 :

Liquid nitrogen

GT:

CCGT060208-MM04 WSM01

SEM:

Scanning electron microscopy

EDS:

Energy dispersive spectrometer

MQL:

Minimal quantity lubrication

\(v\) :

Linear velocity, m/min

\(f\) :

Feed rate, mm/r

\(a_{p}\) :

Cutting depth, mm

\(\kappa_{r}\) :

Entering angle, º

\(S\) :

Spiral distance of the insert, m

\(D\) :

Diameter of the workpiece, m

\(L\) :

Machining length of the workpiece, m

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Acknowledgements

The authors acknowledge the project of Research and Application of Compacted Graphite Cast Iron Cutting Technology supported by Weichai Holding Group, the financial support from the National Key R&D Program of China (2018YFA0703400), distinguished Young Scholars for Science and Technology of Dalian City (2016RJ05), the Xinghai Science Funds for Distinguished Young Scholars and Thousand Youth Talents at Dalian University of Technology, and the Collaborative Innovation Center of Major Machine Manufacturing in Liaoning.

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Authors and Affiliations

  1. Weichai Power Co., Ltd, 197 A, Fushou East Street, High-Tech Development Zone, Weifang, 261061, China

    Ze Ding, Xiaonan Ai, Wei Ma & Kun Wang

  2. Key Laboratory for Precision and Non-Traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian, 116024, China

    Fanning Meng, Xiangdong Meng & Zhenyu Zhang

  3. State Key Laboratory of Catalysis, Dalian Institute of Chemical Physics, Chinese Academy of Sciences, 457Zhongshan Road, Dalian, 116023, China

    Yash Boyjoo

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  1. Fanning Meng
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  2. Ze Ding
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  3. Xiangdong Meng
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  4. Xiaonan Ai
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  5. Zhenyu Zhang
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  6. Wei Ma
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  7. Yash Boyjoo
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  8. Kun Wang
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Correspondence to Xiaonan Ai or Zhenyu Zhang.

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Meng, F., Ding, Z., Meng, X. et al. Research on different cooling methods in the machining of CGI and GCI. Appl Nanosci 10, 2177–2188 (2020). https://doi.org/10.1007/s13204-020-01312-2

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  • DOI: https://doi.org/10.1007/s13204-020-01312-2

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