Effect of the machining parameters on surface roughness and machining noise of heat-resistant nodular cast iron materials

Since the high-temperature corrosion resistance, heat-resistant nodular cast irons or SiMo ductile cast irons are used in the hot end of the exhaust system as an exhaust manifold. In this study, milling behavior of the exhaust manifolds and the effect of some parameters such as surface roughness and noise level were investigated under wet cutting conditions using four-axis horizontal machining center. Experimental studies were realized in a real machining environment using constant cutting speed (120, 240 and 360 m/min), different feed rates (0,20-0,40 and 0.60 mm/rev.) and different depth of cut (0,5- 0,75 and 1,5 mm). The effect of the milling parameters on surface roughness and noise level were analyzed with MINITAB statistical data analysis program. As a conclusion, the surface roughness was remarkably affected from increasing feed rate and depth of cut.