A study of cooling time, copper reduction and effects of alloying elements on the microstructure and mechanical properties of SG iron casting during machining

ABSTRACT

In this work, the effects of alloying elements in the as cast microstructures and mechanical properties of heavy section ductile cast iron were carrying out a systematic to build up press die material having high strength and high ductility the effect of the cooling rate and alloying elements in the microstructures response is particularly analyzed. This experimental study elucidates the problems and machinability issues like failure of drill bit found while machining of casting product and less output in machining. The experiments consisted different cooling rates and alloying elements were measured at specific positions the length of the part. A metallographic analysis is performed. Also, the root causes for less tool life were analyzed and bench mark machinability is achieved. On optimizing the parameters like material composition and solidification time by DOE Design of experiments, a feedback is obtained through which uniform hardness is achieved by attaining identical micro structure at all section thickness. From different trails, it is inferred that solidification time plays a major role in casting hardness. Finally, the solidification time is optimized, uniform hardness is achieved and tool life is enhanced for SG iron casting.

KEYWORDS:

• Spherodised graphite iron (SG iron)
• graphite flakes
• machinability
• hardness

Additional information

Notes on contributors

S. P. Sundar Singh Sivam

S. P. Sundar Singh Sivam received the M. Tech. Degree in Computer Integrated Manufacturing from Anna University. Since 2012, he has been with SRM University as an Asst Professor at the Department Of Mechanical Engineering. His research interests include Sheet Metal Forming, Manufacturing Management & Surface Machining and Optimization. He is the author and Co Author of Many published papers on applications of Sheet Metal Formability, Machining Optimization & Manufacturing Management.

A. Rajasekaran

A. Rajasekaran, received the M.SC Engineering in Engineering Design from the Madras University. Since 2011, he has been with SRM University as an Asst Professor at the Department Of Mechanical Engineering. His research interests include Sheet Metal Forming & Manufacturing Management. He is having 34 Years of Experience in Industry.

S. RajendraKumar

S. RajendraKumar, received the M.E Degree in Thermal Engineering from Anna University. Since 2009, he has been with SRM University as an Asst Professor at the Department Of Mechanical Engineering. His research interests include Heat exchanger, cooling towers. He is the author and Co Author of Many published papers.

K. SathiyaMoorthy

K. Sathiyamoorthy Karuppiah working as an Assistant Professor and therapist in alternative energy medicine. His Research areas are Triorigin Sujok and Energy For the future.