Comparative Analysis of Ductile Metals vs Compacted Graphite Iron Under Machining Conditions: Final Report

Quaker Chemical, Group 1

-Talal Al-Quassar -Bethany Ford -Robert Conrad -Philip Jaunzemis

-Patrick Reilly

4/16/2013

Background
The objective of this project is to test the machinability of Compacted Graphite Iron (CGI) and two ductile metals (80-55-06 and 65-45-12) with the use of three coolants: Quakercool 3750, Quakercool 7020-CG, and Quakercool 7020-CG-2.5
The cutting tools (Kennametal CNMA KCK05) were used as the test for machinability Tool wear was measured after a certain number of cuts to examine how well the coolants were working

Cutting Parameters Ductile

1300 Surface Feet Per Minute
Right Hand Turning Tool Varying Level Cuts

5 Levels (separated by 2 inches) 1.6 inches in depth per level.

Ductile 80-55-06 7020 Coolant

1st Level 10 completed Passes 0.347 mm Tool Wear

5th Level 50 completed Passes 0.714 mm Tool Wear

Ductile 80-55-06 7020 2.5 Coolant

1st Level 10 completed Passes 0.362 mm Tool Wear

5th Level 50 completed Passes 0.861 mm Tool Wear

Ductile 80-55-06 3750 Coolant

1st Level 10 completed Passes 0.297 mm Tool Wear

5th Level 50 completed Passes 0.823 mm Tool Wear

Ductile 65-45-12 3750 Coolant

2nd Level 20 completed Passes 0.293 mm Tool Wear

5th Level 50 completed Passes 0.659 mm Tool Wear

Ductile 65-45-12 7020 Coolant

2nd Level 20 completed Passes 0.278 mm Tool Wear

5th Level 50 completed Passes 0.636 mm Tool Wear

Ductile 65-45-12 7020 2.5 Coolant

2nd Level 20 completed Passes 0.312 mm Tool Wear

5th Level 50 completed Passes 0.636 mm Tool Wear

Cutting Parameters CGI

1300 Surface Feet Per Minute
Right Hand Turning Tool Scale removal process:

Machines off up to 7 inches of the surface. Machines down to 5.645 inches in diameter.
Varying Level Cuts

9 Levels (separated by 0.5 inches) 0.08 inches in depth per level.

CGI 7020 Coolant

Level 20 completed Passes 0.324 mm Tool Wear

4th

9th Level 45 completed Passes 0.454 mm Tool Wear

CGI 7020 2.5 Coolant

4th Level 20 completed Passes 0.335 mm Tool Wear

9th Level 45 completed Passes 0.450 mm Tool Wear

CGI 3750 Coolant

4th Level 20 completed Passes 0.301 mm Tool Wear

9th Level 45 completed Passes 0.480 mm Tool Wear

Microstructure

CGI Bulk Material at 20x

65-45-12 Bulk Material at 20x

80-55-06 Bulk material at 20x

CGI

CGI 7020 Coolant at 20x

CGI 7020-2.5 Coolant at 20x

CGI 3750 Coolant at 20x

80-55-06

7020 Coolant at 50x

3750 Coolant at 50x

7020-2.5 Coolant at 50x

65-45-12

7020-2.5 Coolant at 50x

7020 Coolant at 50x

3750 Coolant at 50x

Tool Wear by Pass 80-55-06

Tool Wear by Pass 65-45-12

Tool Wear by Pass CGI

Analysis
It can be seen from the graphs presented that, although tool wear values seem similar, there is a difference in which section of the tool curve the values are arriving at
7020, in terms of the graphs, is wearing the slowest over time since it is in the plateau phase for both the 80-55-06 and the CGI 7020-2.5 wears slower for the 65-45-12 than both the 3750 and 7020

Regression Analysis
Regression Equation: y = 0.766 - 0.156x1 - 0.338x2 + 0.0527x3 + 0.0477x4

Predictor Constant x1 x2

Coefficient 0.76589 -0.15567 -0.338

SE Coefficient 0.03218 0.03525 0.03525

T 23.8 -4.42 -9.59

P 0 0.012 0.001

x3
x4

0.05267
0.04767

0.03525
0.03525

1.49
1.35

0.21
0.248

Conclusions and Recommendations

It can be seen from the graphs above that Quakercool 7020 will have the longest tool life for the 80-55-05 ductile iron and CGI
Additionally, the 7020-2.5 will have the longest tool life based off of the graph for 65-45-12 This is based on the idea that these lubricants are not yet in the final phase of tool life as compared to the other coolants in their respective categories