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Article

Assessment of the Functional Properties of the Surfaces of Ductile Cast Iron Parts

by
Daniel Grochała
1,*,
Marcin Jasiewicz
1,
Krzysztof Filipowicz
2,
Arkadiusz Parus
1,
Bartosz Powałka
1,
Rafał Grzejda
1 and
Paweł Zmarzły
3,*
1
Faculty of Mechanical Engineering and Mechatronics, West Pomeranian University of Technology in Szczecin, 70-310 Szczecin, Poland
2
Dynpap Sp. z o. o., 71-642 Szczecin, Poland
3
Faculty of Mechatronics and Mechanical Engineering, Kielce University of Technology, 25-314 Kielce, Poland
*
Authors to whom correspondence should be addressed.
Appl. Sci. 2024, 14(19), 9129; https://doi.org/10.3390/app14199129
Submission received: 10 September 2024 / Revised: 27 September 2024 / Accepted: 7 October 2024 / Published: 9 October 2024
Browse Figures
Versions Notes

Abstract

:
Modern technology allows ductile cast iron parts to be efficiently machined while ensuring a relatively long tool life. One of the basic indices describing the susceptibility of ductile cast irons to change in volume, shape, and dimensions under machining conditions is their machinability. Machinability can be expressed directly in terms of the values of basic quantities such as periodic cutting speed and roughness. At the same time, machinability is a relative quantity evaluated alternatively. This means that the machinability of ductile cast iron can be good, allowing high cutting speeds to be achieved, but it can also be poor, expressed in terms of poor surface quality. In the experimental research carried out, an attempt was made to determine the limit values of the cutting speed, beyond which one should not exceed, in order to increase the efficiency of the machining process. The surface roughness, unlike the periodic cutting speed, is a quantity defined in the product design documentation, so its limits must be observed. In addition to the usual indices of surface geometric texture, the research analysed alternative indices for determining the condition of surface geometric texture and the influence of periodic cutting speed on their values. In the conclusions, valuable recommendations are given for designers and technologists on the purpose and functionality of product surfaces and how to define them. Methods of specifying tribological characteristics, hydrophobic or hydrophilic properties, as well as the ability to retain fluids and maintain protective coatings of ductile cast iron parts after machining are described, for which relative values, depending on the machining parameters used, can vary from about 10 to even 30%.

1. Introduction

Ductile cast irons, especially cast iron grade EN-GJS-600-3 [1,2], are particularly popular for production in the engineering, automotive, or machine tool industries [3,4,5]. The main advantages of this material are its low price, good castability, and low costs associated with casting preparation. The strength of ductile cast irons is at a level similar to that of typical carbon steel grades [6]. At the same time, almost all ductile cast iron grades are characterised by good machinability [7] and a high vibration damping coefficient [8], which makes them popular for use in the construction of body components (such as hubs, heads, and housings) of equipment operating under highly stressed conditions and equipment exposed to vibration [9,10] joined to other components by multi-bolted connections [11,12,13,14].
EN-GJS-600-3 ductile cast iron has a hardness between 190 and 270 HBW [15]. However, specific cutting resistance for cast iron is usually slightly lower compared to steel. It mainly depends on the hardness and is usually in the range of 1400 to 1500 N/mm2. EN-GJS-600-3 ductile cast iron has a fairly high carbon content (about 3.7 ± 0.2%) and a relatively high content of hard silicon particles (about 2.7 ± 0.4%) against a soft matrix. This makes this material extremely ‘aggressive’ to the cutting tool material. One of the more common recommendations when machining parts from this material is to use tools with cutting inserts of negative geometry to guarantee high tool life (chipping resistance) of the cutting blades [16,17,18]. On the other hand, protective coatings based on aluminium oxides and fine-grain carbide cutting inserts are recommended to increase the wear resistance of cutting inserts. In turn, the selection of appropriate technological parameters for cast iron machining is an important practical issue, especially in terms of the requirements for the state of the geometric texture of the surface set by constructors and ensuring high volumetric efficiency and stable machining by technologists [19].
The machinability of cast iron is one of the basic indicators describing its susceptibility to change in volume, shape, and dimensions [19]. Machinability can be expressed directly by values of basic quantities such as periodic cutting speed and roughness. As a rule, an increase in the periodic cutting speed contributes to faster tool wear (due to an increase in cutting resistance and temperature in the cutting zone). Therefore, there is a natural limit to the maximum value of the periodic cutting speed, beyond which it should not be exceeded when following the desire to improve the machinability of the material.
Maintaining a balance between machining parameters such as feed rate and turning speed is one technique for addressing machinability issues. Baek et al. [20] conducted simulation and experimental studies to develop a model for estimating surface roughness. They showed that surface roughness increases with increasing feed rate. With respect to spindle speed and feed rate per tooth, Lee et al. [21] adjusted the depths of the cut. To simulate the measured surface roughness, they were able to create a fairly accurate simulation model. In order to obtain a better surface quality within the roughness parameters, some researchers [22,23,24,25,26] have conducted studies changing the machining parameters. Simunovic et al. [22] created a regression model and a neural network model to predict surface roughness, which resulted in good agreement with the experiment. Considering the cutting parameters and cutting tool geometry in the model, Felhő et al. [23] developed a method to predict further surface quality. By simulating the surface roughness profile, Denkena et al. [24] fitted the simulated data to the experiment to obtain a prediction model. Kumar et al. created a model consisting of cutting speed, feed rate, and depth of cut to demonstrate the influence of cutting parameters [25]. Binali and Kuntoğlu [26] showed that feed rate is the most influential parameter on surface quality, as observed for EN-GJS-500-7 ductile cast iron [1]. Studying the material characteristics and microstructure is also considered as a way to understand how the material behaves during machining. For example, Cakir et al. [27] explored the effect of the microstructure of ductile iron on machinability. Aşkun et al. [28], on the other hand, considered cutting forces in addition to the effect of microstructure.
Due to the ambiguity in determining the machinability of the material resulting from changes in the periodic cutting speed with the progress of the machining product, the second of the basic machinability indices, i.e., roughness, is a better criterion for its assessment. Roughness, unlike the periodic cutting speed, is a quantity bound by and defined in the product design documentation (and/or process documentation). Therefore, its limit value should be respected, as well as other parameters related to the geometrical accuracy of the product [29,30,31]. The value of the chosen roughness index is usually expressed by numbers, which is an absolute value for comparison [32,33,34]. This is regardless of the fact that roughness is usually assessed in alternative ways, i.e., as good (below the acceptance level of the selected index value) and as bad (above the acceptance level of the selected index value) [35].
Research on the relationship between machinability and surface roughness of cast iron parts has been carried out in several works. Teke et al. [19] examined the machinability of EN-GJS-600-3 ductile cast iron from the point of view of the relationship between material microstructure and surface roughness. They showed that when machining settings are constant, there is a relationship between microstructure and surface quality. Ghani et al. [36] investigated the flank wear and surface roughness when machining gray cast iron with mixed ceramic tools. They found that the flank wear largely increased with cutting speed, while feed rate had the greatest effect on surface roughness. Sarma and Dixit [37] studied the evolution of surface roughness and mixed ceramic tool life during dry and compressed air-lubricated machining of gray cast iron. They found that for speeds higher than 400 m/min and compared to dry machining, compressed air machining provided good surface quality and increased tool life. Yücel and Günay [38] examined the surface roughness and cutting forces generated when turning two white cast irons of different hardness with cubic boron nitride and ceramic tools. The results showed that feed rate was the main parameter affecting surface roughness, while depth of cut had the greatest effect on cutting force. They also described the application of the Taguchi method to determine the optimum surface roughness in turning high-alloy white cast iron [39]. Kulkarni et al. [40] investigated the effect of cutting parameters on surface roughness when machining gray cast iron with carbide tools and concluded that surface roughness mainly depends on the feed rate and the cutting radius. Ramji et al. [41] studied the wear evolution of carbide-cutting tools when turning gray cast iron. The results of their analysis showed that the cutting speed had the greatest influence on the flank wear of the tools. Laouissi et al. [42] presented a comparative study of both surface roughness and tangential cutting force obtained when machining EN-GJL-250 cast iron [43] with uncoated and coated silicon nitride ceramics. Better surface quality and lower cutting force were obtained with the coated ceramic tool than those achieved by the uncoated ceramic.
The review has shown that, to date, the literature provides little information related to changes in machinability and the influence of technological machining parameters on the formation of surface geometrical texture indices related to their functionality in the case of parts made of EN-GJS-600-3 ductile cast iron. Hence, the need arose to carry out a relevant diagnosis on this topic during experimental work.

2. Materials and Methods

2.1. Evaluation of the Machinability of Cast Iron by the Geometric Texture State of the Surface

The occurrence of unstable conditions in the roughing and shaping milling of EN-GJS-600-3 ductile cast iron causes vibrations that adversely affect machinability (by limiting the range of free selection of the periodic cutting speed). However, for surface quality reasons, this effect can be neglected, as most often in roughing and shaping operations, surface roughness is not an important technological requirement. It only becomes important during finishing passes.
Defining acceptance criteria for the realisation of stable machining conditions is very important. In addition to the CNC machine operator’s subjective perception of stable or unstable machining conditions, there are a number of objective, i.e., quantitative evaluation methods. The values of surface profile indices are the most commonly used for this purpose. Modern surface metrology allows the definition of a very broad set of indices of the geometrical structure of a surface for a 2D or 3D profile related to its height, functionality or load-bearing capacity. In addition to indices characterising standard functional properties, so-called hybrid indices are increasingly used, characterising the service properties of the product surface and indices related to qualitative assessment, i.e., the type and direction of the produced texture. The description of the conditions for measuring the spatial state of the geometrical texture of the surface in the construction documentation is regulated, as shown in Figure 1.
There is still no awareness among design engineers of the new possibilities related to the description of the technological and functional requirements of surfaces. This state of affairs is probably due to the fact that the method of determining the parameters used to describe the spatial state of the geometrical texture of a surface has been regulated by ISO standards relatively recently. Part of the standardisation work related to the ISO 25178 family of standards [44,45,46] (associated with measurement methodology) is still ongoing.
Depending on the surface technology, its purpose, and the way it is used, the method of noting the functional requirements is very important. In construction documentation, the use of the roughness parameters Ra, Rz, Rt, and Rmax has become most common for this reason. In recent years, one can see a similar analogy and a gradual spread of the use of parameters such as Sa, Sq, and Sz in the description of surface topography [32,33,34]. However, the above parameters say very little about the functionality of the surface. With a similar height of roughness, surfaces may have different load-bearing capacities and may be isotropic or anisotropic. In the area of a surface with similar Sa parameter values, there may be different numbers of valleys and peaks with different volumes. These valleys, peaks, and cracks can provide a point of attachment for lubricants. A suitable surface texture can increase the load-bearing capacity of the surface or determine the hydrophilic capacity of the finished product.
Surface topographical analysis is very often used to investigate the degree of isotropy. Parts shaped by machining, where the roughness is influenced by the regular geometry of the tool and the kinematic conditions of the process, are generally characterised by anisotropic surfaces. In contrast, fine oscillating finishing operations such as honing and polishing, as well as abrasive blasting, lead to non-directional-isotropic surfaces with different height values of the geometric texture parameters of the surface. Often, the resulting surface of the finished product is the result of mapping another surface, such as a tool. This is the case when moulding castings in sand moulds or when shaping plastic moulded parts in high-precision pressure moulds.

2.2. Studies on the Influence of Technological Machining Parameters on the Formation of Functional Properties of the Geometrical Texture of the Surface

Machining tests were carried out on a MIKRON VCE 500 triaxial machining centre (Haas Automation, Inc., Oxnard, CA, USA), shown in Figure 2, using three typical tools applied in the finishing treatment of cast parts described in Table 1. Specimens made of EN-GJS-600-3 ductile cast iron were tested.
A representative range of technological machining parameters was selected for the prepared tools in accordance with the manufacturer’s recommendations, as summarised in Table 2. In the prepared experiment, an attempt was also made to determine unstable machining conditions. For this purpose, it was planned to carry out tests with a feed rate per blade exceeding the manufacturer’s recommended value, indicated in Table 2 by the superscript 1. However, these tests were only performed for specimens with tools N1 and N3.
The experimental plan included testing 44 experimental setups resulting from all combinations of the parameter values in Table 2 and three tool types (see Table 1). Machining was repeated three times for each of the 44 setups, obtaining a total of 132 specimen surfaces for which the surface condition texture was analysed.
During the machining of the specimens, force and acceleration measurements were recorded using two sensors: a six-component Kistler 9265b piezoelectric force gauge (Kistler Instrumente AG, Winterthur, Switzerland) mounted between the machine table and the milled specimen and a three-component PCB 356A01 acceleration sensor (PCB Piezotronics, Depew, NY, USA) associated with the machined specimen.
The prepared test stand, together with additional measuring systems, is shown above in Figure 2. On the prepared test fields (machined specimen surfaces), the qualitative criteria of ductile cast iron machinability were evaluated, and the effects of unstable machining processes were sought.
A Mitutoyo HYPER WLI optical scanning system (Mitutoyo Corporation, Sakado, Japan) with an interferometric head was used to measure the geometric texture of the surface of the specimens under the study. Depending on the type of tool used for processing (N1, N2, or N3), measurements were made on the specimens by digitising the surface, resulting in a point cloud of approximately 29 million to more than 60 million points. More precisely, the parameters associated with the point cloud acquisition of the measured surfaces are summarised and presented in Table 3.
Surface measurements were taken repeatedly on specimens in order to select a representative location (to avoid coarse errors). In addition, a qualitative analysis of the resulting point cloud was carried out before determining the values of selected indicators of the geometric structure of the surface. In contrast, measurement errors and uncertainties in the results were not determined during the measurements of the geometric structure of the surface. This is because the primary objective of the research was to determine the cutting and quality conditions associated with the machining of ductile cast iron parts. Care was taken to eliminate random errors and maintain measurement consistency by calibrating the Mitutoyo HYPER WLI measuring system (Mitutoyo Corporation, Sakado, Japan) before each series of measurements. The acclaimed MCubeMAP software version 8.1 (Mitutoyo Corporation, Sakado, Japan) was used to image the state of the geometric structure of the surface.

3. Results

3.1. Surface Maps

The point cloud was initially levelled with the LS mean plane (by subtraction and rotation) and then filtered with a high-pass Gaussian filter (Lambda C intended for roughness) of 0.8 mm to visualise the surface condition. Examples of surface images are presented in Figure 3, Figure 4 and Figure 5. Due to the low inherent noise of the measurement system used, the low-pass Lambda S filter (normally used to filter out measurement noise and/or so-called micro-roughness) was not used.

3.2. Indices of Geometric Condition of the Tested Surfaces

The following indices were used to assess the height of the shaped irregularities on the tested surfaces [44,45,46]:
  • Sa—arithmetic mean deviation of the surface points from the mean line (μm);
  • Sq—mean square deviation of the surface points from the mean line (μm).
The values of the indices Sa and Sq are summarised in Figure 6 for all 44 setups studied.
In addition, the following indices were used in the surface elevation analysis, which report peak heights and valley depths in relation to the mean line [47]:
  • Sp—maximum peak height (µm);
  • Sv—maximum valley depth (µm).
The values of the indices Sp and Sv are shown in Figure 7 for all 44 setups studied.
The following indices were selected to assess the influence of changes in machining parameters on the development of volumetric indices of the geometric texture of surfaces [47,48]:
  • Vm(p)—material volume at material ratio p expressed as a percentage (mm3/mm2);
  • Vmp—material volume in the hill region (mm3/mm2);
  • Vv(p)—void volume at material ratio p expressed as a percentage (mm3/mm2);
  • Vvc—void volume within the core (mm3/mm2);
  • Vmc—material volume within the core (mm3/mm2);
  • Vvv—void volume below the core (mm3/mm2).
The values of the volumetric indices are shown in Figure 8, Figure 9 and Figure 10 for all 44 setups studied.

3.3. Surface Wettability

The indices of the geometric texture of a surface related to surface wettability allow the tribological properties of cooperating surfaces to be defined. They are also often used to determine the conditions under which this cooperation will be improved, for example, by selecting appropriate lubricants (their type and viscosity). This is due to the desire of machine and equipment manufacturers to continuously increase the durability of their products and achieve full control over the course of their wear (if only to reduce the costs associated with providing manufacturer’s warranties). The interest in surface wettability indices should be explained by the specific operating conditions of products, for which it is important to provide hydrophobic or hydrophilic properties. Therefore, the work described in this article also presents an evaluation of the quality criteria related to changes in the machinability of ductile cast iron by means of indices such as [44,45,46]:
  • Sbi—surface bearing capacity index (no unit);
  • Sci—surface core fluid retention index (no unit);
  • Svi—surface valley fluid retention index (no unit).
Combining the values of the above-mentioned indices (related to wettability) with the values of the volumetric parameters allows an additional assessment of the need for surface protection measures, e.g., by coating with paint or varnish. The values of the indices related to wettability are shown in Figure 11 and Figure 12 for all 44 setups studied.

4. Discussion

4.1. Surface Maps

The recorded colour surface maps allowed a preliminary assessment of the machinability of ductile cast iron. It was shown that, in addition to the satisfactory kinematic and geometric effects associated with the direct execution of the cutting process, the characteristics of difficult-to-machine materials become apparent on the surface. Besides regular milling cutter marks and the typical anisotropic texture (with one or two dominant directions) [49,50], a number of bumps, creases, ridges, and irregularly shaped pores remained at random locations on the machined surface. These effects were observed on all surfaces shaped with different tools, regardless of whether the tool was equipped with new (sharp) cutting inserts or partially worn (within the limits of acceptable abrasion on the contact surface).

4.2. Indices of Geometric Condition of the Tested Surfaces

In the case of the surfaces of currently manufactured machine parts, it is becoming very important to ensure that they have the required ability to retain protective coatings, lubricants as well as paint coatings (see [51] for comparison). In this way, the functionality of modern equipment and machinery is improved, allowing longer periods of trouble-free operation. Often, in the design documentation, as supplementary conditions to the required state of the geometrical texture of the surface (described by amplitude-related indices), one encounters indices related to the volume of the surface (its cavities and/or vertices). By appropriately controlling the process technology during finishing, it is possible to significantly improve the conditions of the mating parts while also contributing to shortening the so-called run-in period.
Clearly visible against the material volume of the surface Vm are the significant void volumes Vv (Vv >> Vm), which clearly indicates the low load-bearing capacity of such a surface and has implications for plastic damage mechanisms [52]. Parts that are finish-machined at low and medium feed rates will be characterised by increased abrasive wear in the initial period of use. Although the values of the amplitude parameters (Sq, Sa) are low, there will be considerable play (a very unfavourable phenomenon) between the surfaces of the parts during the initial period of cooperation. It appears that a sure way to improve the conditions of cooperation under frictional conditions of the part surface is to introduce lubricants. Under finishing cutting conditions, a favourable surface can be produced, characterised by a relatively large volume of lubricants in the voids in the core of the material Vvc with relatively small volumes of voids in the valleys of roughness Vvv. The product will be characterised by its ability to become so-called self-lubricating after a rapid run-in through the lubricant held on the surface for an extended period. The surface of the machined cast iron should also be characterised by good coating retention properties (Vmc >> Vmp); namely, the volume of surface peak material is relatively small, and they are evenly distributed over the entire surface. Thanks to such properties, a favourable effect of the so-called mechanical anchoring of the coating is to be expected, an effect that will be enhanced due to the voids present in the core of the material Vvc.

4.3. Surface Wettability

On the basis of the distribution of the obtained Sbi values, it can be seen that the resulting milling irregularities are characterised by a significant plateau of Sbi << 0.3. In combination with the low values of fluid retention capacity in the valleys, this represents a continuous need for the introduction of lubricants between the mating surfaces of the parts or the introduction of low-viscosity lubricants capable of penetrating the depressions in the lubricating pockets created. The effect of favourable self-lubricity described in the earlier part of the analysis will disappear once a plateau is reached. This means a situation in which a significant amount of lubricant will be retained in the core of the surface. Over long periods of operation, product surfaces shaped in this way will be a gradual loss of their lubricating film. Depending on the treatment, the value of this index varies from 20 to as much as 50%.
By analysing the fluid retention capacity of the surface core (Sci-index values), it can be concluded that changing the machining method (feed per blade, depth of cut, or wrapping angle) does not affect the surface characteristics. The changes observed during the study do not exceed 10% except in one case. This is good information for economic process design.

5. Conclusions

The following findings can be drawn on the basis of the experimental tests carried out and the measurements of the surface topography of the tested specimens:
  • Ductile cast iron alloys are characterised by good machinability in terms of the periodic cutting speed as well as the qualitative effects of the resulting surface;
  • Good machinability translates into a stable machining process. Experimental work has shown that the machining process is stable over the entire range of machining parameters. Some difficulties (sensitivity of the process to the formation and development of self-excited vibrations) are noted under roughing conditions. The qualitative results of the surfaces obtained under these conditions in mechanical engineering are unsatisfactory. In such cases, it is noted that the values of the geometrical texture indices of the surface used as standard for defining the functionality of the part surface (e.g., Sa less than 3.2 µm and Sz less than 25 µm) are significantly exceeded;
  • It is fairly easy to meet the surface quality requirements when cutting EN-GJS-600-3 ductile cast iron under finishing conditions. The material aspects associated with the disruption of the cutting process, which is caused by ferrite in ball form [53], do not contribute significantly to the reduction of the surface geometrical structure indices. The process is stable, and the surface condition is predictable;
  • Layered inhomogeneities and inclusions present in the cast iron alloy contribute significantly to the quality of the machinable surface. The rearrangement in the deeper layers beneath the product surface results in the detection during the shaping and finishing milling of cracks and pores that were previously not visible. Visible surface faults occur, especially in the softer graphite phases contributing to surface burrs and collapse. An increase in surface roughness height is thus observed as the feed and depth of cut are changed in combination with a constant cutting speed;
  • As a result of an inadequate material structure, the cutting process can become uncontrollable, but this does not necessarily imply a deterioration in machinability as assessed by the criterion of a high periodic cutting speed;
  • The surface of machined cast iron is characterised by a relatively small number of high peaks, which contribute to a reduction in its load-bearing capacity. Machine and equipment parts manufactured from this material must initially be lapped, or lapping (and/or honing) treatments must be designed into the process to reduce these peaks;
  • The milled surfaces of cast iron parts are characterised by satisfactory fluid retention values, and the large volume spaces created during the cutting of softball graphite phases (in the core and valley bottoms) become pockets in which lubricant can accumulate (thus improving the self-lubricating properties of the mating product surfaces).

Author Contributions

Conceptualisation, D.G., K.F., and M.J.; methodology, D.G. and B.P.; software, A.P.; validation, A.P. and B.P.; formal analysis, B.P.; investigation, D.G., K.F., and M.J.; resources, D.G.; data curation, A.P. and M.J.; writing—original draft preparation, D.G. and R.G.; writing—review and editing, M.J. and A.P.; visualisation, D.G. and B.P.; supervision, B.P. and P.Z.; project administration, R.G.; funding acquisition, P.Z. All authors have read and agreed to the published version of the manuscript.

Funding

This research received no external funding.

Institutional Review Board Statement

Not applicable.

Informed Consent Statement

Not applicable.

Data Availability Statement

The data presented in this study are available on request from the corresponding authors.

Conflicts of Interest

Author Krzysztof Filipowicz was employed by the Dynpap Sp. z o. o. The remaining authors declare that the research was conducted in the absence of any commercial or financial relationships that could be construed as a potential conflict of interest.

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Figure 1. Systematics of marking the requirements of the spatial state of the geometric texture of the surface in the construction documentation (see for comparison [44]): (a) Example of the use of a graphic symbol; (b) Abbreviated text symbol; (c) Detailed graphic symbol describing the method of processing the collected point cloud.
Figure 1. Systematics of marking the requirements of the spatial state of the geometric texture of the surface in the construction documentation (see for comparison [44]): (a) Example of the use of a graphic symbol; (b) Abbreviated text symbol; (c) Detailed graphic symbol describing the method of processing the collected point cloud.
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Figure 2. Test stand with a diagnostic system for monitoring the stability of the machining process.
Figure 2. Test stand with a diagnostic system for monitoring the stability of the machining process.
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Figure 3. View of the surface after machining with the N1 tool with a wrapping angle of 180° at a cutting speed of 100 m/min and a depth of cut equal to (a) 0.5 mm; (b) 1.0 mm (test setups 1 and 2).
Figure 3. View of the surface after machining with the N1 tool with a wrapping angle of 180° at a cutting speed of 100 m/min and a depth of cut equal to (a) 0.5 mm; (b) 1.0 mm (test setups 1 and 2).
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Figure 4. View of the surface after machining with the N2 tool with a wrapping angle of 180° at a cutting speed of 100 m/min and a depth of cut equal to (a) 0.5 mm; (b) 1.0 mm (test setups 17 and 18).
Figure 4. View of the surface after machining with the N2 tool with a wrapping angle of 180° at a cutting speed of 100 m/min and a depth of cut equal to (a) 0.5 mm; (b) 1.0 mm (test setups 17 and 18).
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Figure 5. View of the surface after machining with the N3 tool with a wrapping angle of 180° at a cutting speed of 100 m/min and a depth of cut equal to (a) 0.5 mm; (b) 1.0 mm (test setups 33 and 34).
Figure 5. View of the surface after machining with the N3 tool with a wrapping angle of 180° at a cutting speed of 100 m/min and a depth of cut equal to (a) 0.5 mm; (b) 1.0 mm (test setups 33 and 34).
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Figure 6. Values of indices Sa and Sq obtained during the machinability tests of EN-GJS-600-3 ductile cast iron.
Figure 6. Values of indices Sa and Sq obtained during the machinability tests of EN-GJS-600-3 ductile cast iron.
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Figure 7. Values of indices Sp and Sv obtained during the machinability tests of EN-GJS-600-3 ductile cast iron.
Figure 7. Values of indices Sp and Sv obtained during the machinability tests of EN-GJS-600-3 ductile cast iron.
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Figure 8. Values of indices Vm(p) and Vmp obtained during the machinability tests of EN-GJS-600-3 ductile cast iron.
Figure 8. Values of indices Vm(p) and Vmp obtained during the machinability tests of EN-GJS-600-3 ductile cast iron.
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Figure 9. Values of indices Vv(p) and Vvc obtained during the machinability tests of EN-GJS-600-3 ductile cast iron.
Figure 9. Values of indices Vv(p) and Vvc obtained during the machinability tests of EN-GJS-600-3 ductile cast iron.
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Figure 10. Values of indices Vmc and Vvv obtained during the machinability tests of EN-GJS-600-3 ductile cast iron.
Figure 10. Values of indices Vmc and Vvv obtained during the machinability tests of EN-GJS-600-3 ductile cast iron.
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Figure 11. Values of indices Sbi and Svi obtained during the machinability tests of EN-GJS-600-3 ductile cast iron.
Figure 11. Values of indices Sbi and Svi obtained during the machinability tests of EN-GJS-600-3 ductile cast iron.
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Figure 12. Values of indices Sci obtained during the machinability tests of EN-GJS-600-3 ductile cast iron.
Figure 12. Values of indices Sci obtained during the machinability tests of EN-GJS-600-3 ductile cast iron.
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Table 1. Parameters characterising the tools used in the experimental studies.
Table 1. Parameters characterising the tools used in the experimental studies.
Tool
Type		Diameter (mm)Number of Tool BladesTool Overhang (mm)Insert TypeCasing Type
N116475R390-11T3 04M-PM 4220 1Ø16 AEM90 R390.11 W16 L150 2
N230495R390-11T3 04M-PM 4220 1Ø30 AEM90 R390.11 W25 L150 2
N36425monolithic cutterP8300300 3
1 Sandvik Coromant, Sandviken, Sweden, 2 Akko Cutting Tools Company, Konya, Turkey, 3 Fraisa SA, Bellach, Switzerland.
Table 2. Values of technological processing parameters adopted during experimental tests.
Table 2. Values of technological processing parameters adopted during experimental tests.
ParameterUnitValues
cutting speed(mm/min)100
depth of cut(mm)0.5, 1.0
wrapping angle(°)120, 180
feed per blade(mm/blade)0.01, 0.05, 0.1, 0.3 1
1 Feed rate per blade exceeding the manufacturer’s recommended value.
Table 3. Conditions for the acquisition of the geometric texture of the surface of the test specimens.
Table 3. Conditions for the acquisition of the geometric texture of the surface of the test specimens.
Tool
Type		Length of Measuring Axis in X Direction (mm)X-Axis Point Spacing (μm)Length of Measuring Axis in Y Direction (mm)Y-Axis Point Spacing (μm)Average Number of Non-Measured Points (%)Point Cloud Size (MPx)
N11.040.1971.080.1983.0528.7
N21.540.1971.540.1981.6260.7
N31.540.1971.540.1980.8860.7
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MDPI and ACS Style

Grochała, D.; Jasiewicz, M.; Filipowicz, K.; Parus, A.; Powałka, B.; Grzejda, R.; Zmarzły, P. Assessment of the Functional Properties of the Surfaces of Ductile Cast Iron Parts. Appl. Sci. 2024, 14, 9129. https://doi.org/10.3390/app14199129

AMA Style

Grochała D, Jasiewicz M, Filipowicz K, Parus A, Powałka B, Grzejda R, Zmarzły P. Assessment of the Functional Properties of the Surfaces of Ductile Cast Iron Parts. Applied Sciences. 2024; 14(19):9129. https://doi.org/10.3390/app14199129

Chicago/Turabian Style

Grochała, Daniel, Marcin Jasiewicz, Krzysztof Filipowicz, Arkadiusz Parus, Bartosz Powałka, Rafał Grzejda, and Paweł Zmarzły. 2024. "Assessment of the Functional Properties of the Surfaces of Ductile Cast Iron Parts" Applied Sciences 14, no. 19: 9129. https://doi.org/10.3390/app14199129

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