Batch-to-Batch Material Variations’ Effects on Cast Iron Machining Description:
Inconsistent tool wear costs time and money. This project targets the root cause – material variability in cast iron – to make machining outcomes more predictable.
Project description
A key aspect of ensuring a robust machining process is known and predictable tool wear. Ideally, using the same types of tools and processes while producing components from the same material would yield consistent tool wear. However, due to variations primarily introduced during the casting of these components, noticeably different tool wear can occur during machining. Factors such as specific material composition, the amount and morphology of non-metallic inclusions (NMIs), as well as the mechanical properties of the material can vary, not only between parts made at different times but also within the same part. This variability reduces the predictability of the process, leading to cutting tools not being used to their full tool life – ultimately wasting money and resources. To improve the predictability of cast iron machining, these batchwise material variations and their effect on cast iron machining must be further studied.
Outcome
A better understanding of the effects of batch-to-batch material variational effects on machining, leading to increased process robustness and tool life utilization.