Skip to main content
Springer Nature Link
Log in

Enhancing Tool Life in High-Speed Machining of Compacted Graphite Iron (CGI) Using Controlled Modulation

  • Original Paper
  • Published:
Tribology Letters Aims and scope Submit manuscript

Abstract

The application of controlled, low-frequency modulation superimposed onto the cutting process—modulation-assisted machining (MAM)—is shown to be quite effective in reducing the wear of cubic boron nitride (CBN) tools when machining compacted graphite iron (CGI) at high machining speeds (>500 m/min). The tool life is at least one order of magnitude greater than that in conventional machining. The improvement in wear performance is a consequence of a reduction in the severity of the tool–work contact conditions in MAM: reduction in intimacy of the contact, formation of discrete chips, enhanced fluid action, and lower cutting temperatures. The propensity for thermochemical wear of CBN, the principal wear mode at high speeds in CGI machining, is thus reduced. The MAM configuration employing feed-direction modulation appears feasible for implementation at high speeds and offers a potential solution to this challenging class of industrial machining applications.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
$34.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or eBook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7

Similar content being viewed by others

References

  1. Dawson, S.: Compacted graphite iron: mechanical and physical properties for engine design. Paper presented at Materials in Powertrain VDI, Dresden, Germany. SinterCast Tech. Publication (1999)

  2. Dawson, S., Hollinger, I., Robbins, M., Daeth, J., Reuter, U., Schulz, H.: The effect of metallurgical variables on the machinability of compacted graphite iron. SAE Tech. Pap. Ser. 2001-01-0409 (2009)

  3. Abele, E., Sahm, A., Schultz, H.: Wear mechanism when machining compacted graphite iron. Ann. CIRP 51, 53–56 (2002)

    Article  Google Scholar 

  4. Zelinski, P.: Surpassing the speed limit in CGI. Mod. Mach. Shop 76, 102–103 (2003)

    Google Scholar 

  5. Gastel, M., Konetschny, C., Reuter, U., Fasel, C., Schulz, H., Riedel, R., Ortner, H.M.: Investigation of the wear mechanism of cubic boron nitride tools used for the machining of compacted graphite iron and grey cast iron. Int. J. Refract. Met. Hard Mater. 18, 287–296 (2000)

    Article  CAS  Google Scholar 

  6. Heck, M., Ortner, H.M., Flege, S., Reuter, U., Ensinger, W.: Analytical investigations concerning the wear behavior of cutting tools used for the machining of compacted graphite iron and grey cast iron. Int. J. Refract. Met. Hard Mater. 26, 192–206 (2008)

    Article  Google Scholar 

  7. Tasdelen, B., Escursell, M., Grenmyr, G., Nyborg, L.: Machining of gray cast irons and compacted graphite iron. In: Swedish Production Symposium. pp. 1–6 (2007)

  8. Shaw, M.C.: Metal cutting principles. Clarendon Press, Oxford (1984)

    Google Scholar 

  9. Moscoso, W., Olgun, E., Compton, W.D., Chandrasekar, S.: Effect of low-frequency modulation on lubrication of chip-tool interface in machining. J. Tribol. 127, 238–244 (2005)

    Article  Google Scholar 

  10. Mann, J.B., Saldana, C., Moscoso, W., Compton, W.D., Chandrasekar, S.: Effects of controlled modulation on interface tribology and deformation in machining. Tribol. Lett. 35, 221–227 (2009)

    Article  Google Scholar 

  11. Huang, C., Lee, S., Sullivan, J.P., Chandrasekar, S.: In situ measurement of fluid film thickness in machining. Tribol. Lett. 28, 39–44 (2007)

    Article  CAS  Google Scholar 

  12. Moriwaki, T., Shamoto, E.: Ultraprecision diamond turning of stainless steel by applying ultrasonic vibration. Ann. CIRP 40, 559–562 (1991)

    Article  Google Scholar 

  13. Brehl, D.E., Dow, T.A.: Review of vibration-assisted machining. Precis. Eng. 32, 153–172 (2008)

    Article  Google Scholar 

  14. Kumabe, J.: Vibration cutting—basic principle and application. Jikkyo Shuppan Books, Japan (1979)

    Google Scholar 

  15. Mann, J.B., Saldana, C., Chandrasekar, S., Compton, W.D., Trumble, K.P.: Metal particulate production by modulation-assisted machining. Scr. Mater. 57, 909–912 (2007)

    Article  CAS  Google Scholar 

  16. Mann, J.B., Guo, Y., Saldana, C., Compton, W.D., Chandrasekar, S.: Enhancing material removal processes using modulation-assisted machining. Tribol. Int. 44, 1225–1235 (2011)

    Article  CAS  Google Scholar 

  17. Boothroyd, G.: Fundamentals of metal machining and machine tools. McGraw-Hill, New York (1975)

    Google Scholar 

  18. Hutchings, I.M.: Tribology: friction and wear of engineering materials. Arnold, London (1992)

    Google Scholar 

  19. Kountanya, R.: Cutting tool temperatures in interrupted cutting—the effect of feed direction modulation. J. Manuf. Process 10, 47–55 (2008)

    Article  Google Scholar 

Download references

Acknowledgments

This study was supported in part by Diamond Innovations, Inc. (Columbus, Ohio, USA) and a Bilsland fellowship to Yang Guo. We thank M4 Sciences LLC for providing the prototype large-scale MAM system used in the study.

Author information

Authors and Affiliations

  1. Center for Materials Processing and Tribology, School of Industrial Engineering, Purdue University, West Lafayette, IN, 47906, USA

    Y. Guo, J. B. Mann, H. Yeung & S. Chandrasekar

Authors
  1. Y. Guo
    View author publications

    You can also search for this author inPubMed Google Scholar

  2. J. B. Mann
    View author publications

    You can also search for this author inPubMed Google Scholar

  3. H. Yeung
    View author publications

    You can also search for this author inPubMed Google Scholar

  4. S. Chandrasekar
    View author publications

    You can also search for this author inPubMed Google Scholar

Corresponding author

Correspondence to S. Chandrasekar.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Guo, Y., Mann, J.B., Yeung, H. et al. Enhancing Tool Life in High-Speed Machining of Compacted Graphite Iron (CGI) Using Controlled Modulation. Tribol Lett 47, 103–111 (2012). https://doi.org/10.1007/s11249-012-9966-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11249-012-9966-z

Keywords