Cutting Parameter Optimization Of Ductile Cast Irons

Ductile cast iron is widely applied in many kinds of spare parts of mechanical manufacturing industry due to its good impact-resistant performance, high tensile strength, and cast iron's unique and fine castability, wearing resistance, fatigue resistance, economy and so on. In this paper, the formation mechanism of the cutting burr during ductile cast iron processing is analyzed through the finite element modeling and cutting test according to the present manufacturing situation of ductile cast iron in QS companies. Further more, research cutting performance of ductile cast iron, so as to improve product quality, reduce cost and provide process guidance.First, we have analyzed ductile cast iron milling process through the finite element modelling, which indicate that there is the similar regularity of distribution between equivalent effective strain and temperature during the milling process. The cutting burr simulation shows: the temperature increases little by little in the course of burr formation, the burr size is related to the temperature increasing of duration. And the further cutting test shows that the burr will be less influenced by speed and cutting feed, more influenced by cutting depth, the surface roughness decreases along with the rotational speed enhancement, increases along with the cutting feed and the cutting depth increasing. While the cutting speed is lower, the chip is very short and scrap, with the cutting speed increasing, the chip becomes longer. Similarly, when the cutting depth and feed is lower, the chip is scrap, with the cutting depth and feed increasing, the chip becomes longer. When processing the ductile cast iron with hard alloy cutting tools, the invalidation mode is mainly grain attrition.This study shows that DEFORM can simulate the milling process of ductile cast iron effectively. The analysis of equivalent effective stress, equivalent effective strain and temperature chart can provide the guidance for the actual production. The result of this research has been applied to the actual production, after adjusting the process parameter, the cutting burr was effectively controlled, meanwhile the quality of product was also improved.