Surface integrity analysis of grinding on ductile iron
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ORIGINAL ARTICLE
Surface integrity analysis of grinding on ductile iron Mar´ıa Emilia Furno1 · Amadeo Daniel Sosa1 Received: 23 April 2020 / Accepted: 3 August 2020 / Published online: 1 September 2020 © Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Ductile iron (DI) is a widely used material and one of the most largely casts produced. Advances in the understanding of the characteristics and behavior of this material have led to the development of parts with dimensions and shapes close to the final ones, and components with different thickness sections, including thin wall. When certain tolerances of shape and dimension have to be met, an appropriate machining process such as grinding must be chosen. This type of process produces high local efforts and hence a great amount of heat in the contact zone. Nowadays, there is scarce information on the effects of grinding on the surface integrity of DI. A comparative study of the surface finish and surface integrity of DI with different microstructures and nodule counts (NC) under grinding conditions was performed. All ground surfaces exhibited a good finish, and their surface roughness was within the expected range for grinding operations. Microstructure alterations as well as strains were studied and related to hardness alterations. The role played by mechanical and thermal effects on residual stress profiles was analyzed. A clear relationship between distortion and residual stress formation during the grinding process was established. Keywords Surface roughness · Residual stress · Hardness alterations · Distortion · Plastic strain · Microstructure
1 Introduction Cast components claim a major share in the manufacturing industry. To set an example, this type of components accounts for one-sixth of the total weight of an internal combustion engine car [1]. Within the car industry, cast irons are the most largely produced, gray and ductile iron ranking at the top (in terms of metric tons) [2]. This is explained by the fact that ductile iron (DI) is widely used in pipes, car components, agricultural machines, diesel engines, heavy vehicles, and oil well pumps. Besides, one of the highest rates of growth of this cast is forecast to take place in the coming decade, along with investment cast steel and aluminum [3]. DI is a ternary Fe-C-Si alloy, in which almost the largest portion of the carbon is dispersed on a metal matrix in the form of graphite nodules. Even though this material has long
Mar´ıa Emilia Furno
[email protected] 1
Divisi´on Metalurgia – INTEMA – CONICET, Engineering School Universidad Nacional de Mar del Plata, Juan B. Justo 4302, B7608FDQ, Mar del Plata, Buenos Aires, Argentina
been developed, it has evolved significantly over the last decades. David et al. [4] observed that the size, shape, and quantity of graphite nodules are defined by the chemical composition and cooling rate. They found that nodule count (NC) increases with cooling rate and the amount of inoculants. Since heat treatment produces solid-state transformation
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