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A review on the machining of cast irons

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Abstract

Nowadays, the search for new materials is concerning to reduce the relative “efficiency/weight” ratio and its costs, in general, in the whole manufacturing chain, since the design until the final manufacturing stage. The efforts to achieve these requirements must fall in one of two options: (i) selecting “new” materials with similar strength of the “old,” but with low density or (ii) increasing the strength of the existing materials by adding alloying elements or by heat treatment. Choosing the best material for a given application depends on a few parameters such as mechanical loads, thermal environments, manufacturing costs, recycling, public acceptance, and workability. Among several kinds of materials are the cast irons, which almost always provide good machinability and low production cost. Under the scenario of the Industrial Revolution to date, cast iron received great emphasis on its development from the point of view of its properties and economic advantages. Currently, among the metallic materials, cast irons are the second most produced, after steels. They are an extremely important group of metal for the industry because, by introducing alloying elements and applying appropriate heat treatment, their use has become viable in some applications that were exclusively of steels. The several grades and groups available, on the other hand, brings another concern about their machinability. After production on the foundry, cast irons always are processed by machining, involving a large amount of money. With the goal of bringing relevant information on the machinability characteristics of cast irons, this review was produced. It covers the main output parameters in machining (forces and power consumption, cutting temperature, surface roughness, recommended cutting tools, tool wear, and corresponding use of computational modeling technique, by using the finite element method) finalizing with future trends. It is hoped to fill a gap in the literature for those involved with machinability of this important metal.

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Acknowledgements

The authors are grateful to FAPEMIG, CNPq, CAPES, and MMC Metal do Brasil Ltda (Mitsubishi Materials Corp.) for the financial support. One of the authors thanks CAPES (Project number 002659/2015-08 PDS).

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Authors and Affiliations

  1. Federal Technological University of Paraná, Londrina, PR, Brazil

    José Aécio G. de Sousa

  2. Mechanical Engineering Faculty (FEMEC), Federal University of Uberlândia, Uberlândia, Minas Gerais, Brazil

    Wisley Falco Sales & Alisson R. Machado

  3. Mechanical Engineering Graduate Program, Pontifícia Universidade Católica do Paraná – PUC-PR, Curitiba, PR, 80215-901, Brazil

    Alisson R. Machado

Authors
  1. José Aécio G. de Sousa
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  2. Wisley Falco Sales
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  3. Alisson R. Machado
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Corresponding author

Correspondence to Wisley Falco Sales.

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de Sousa, J.A.G., Sales, W.F. & Machado, A.R. A review on the machining of cast irons. Int J Adv Manuf Technol 94, 4073–4092 (2018). https://doi.org/10.1007/s00170-017-1140-1

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  • DOI: https://doi.org/10.1007/s00170-017-1140-1

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