Tool life analysis in interrupted cutting conditions for ductile iron materials

ABSTRACTTOOL LIFE ANALYSIS IN INTERRUPTED CUTTING CONDITIONSFOR DUCTILE IRON MATERIALSAfyon Kocatepe University,Institute for the Natural and Applied SciencesIn this study machinability of a ductile iron which has a ferritic structure wasinvestigated in interrupted cutting conditions. For this purpose, cylindrical samples with1, 2 and 4 axial slots were prepared. In the study, cemented carbide cutting tool wasused. Two different cutting speed, feed rate and depth of cut were chosen as cuttingparameters.According to results, the number of slot seriously affects the tool wear. The increasingof the number of slot results in the decreasing of chip dimension. Especially, thisdecreasing was observed in the higher cutting speed and feed rate. Another resultobserved during the tool wear experiments is that the increasing of the number of slotresults in the increasing of flank wear at the lower feed rate and depth of cut. However,the cutting tool wears out rapidly at higher feed rate or depth of cut when one or twoslotted workpiece are used. Increasing feed rate results in deterioration of surfaceroughness for both continuous cutting and interrupted cutting. Scanning electronmicroscope and EDX analysis of the worn tools showed that abrasive, adhesion andoxidation wear mechanisms are predominant in the machining of continuous andinterrupted cutting of ductile iron. Besides, BUE was observed at continuous cuttingconditions due to adhesion wear mechanism.2007, 72 pageKeywords: Interrupted cutting; Ductile iron; Tool wear; Machinability.