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<p>Gray cast iron (GCI/FC) is widely used in various industrial applications, especially in the automotive industry, such as in engine blocks and brake discs, where machining plays a crucial role in manufacturing these components. In modern machining, the proper selection of cutting parameters and cooling-lubrication methods is essential not only to reduce costs but also to ensure precise geometric tolerances, high-quality surface finish, and compliance with environmental and occupational health standards. To address the challenges associated with the use of conventional cutting fluids, which have negative impacts on the pillars of the triple bottom line (TBL)—economic, social, and environmental—this study proposed the development of an internally cooled tool (ICT) system. In this system,&#xa0;a cooling&#xa0;fluid circulates exclusively through the tool and tool holder, avoiding direct contact with the workpiece and the operator. This innovative approach contributed to reducing environmental impacts, minimizing health risks to the operator, and lowering the costs associated with the acquisition and disposal of cutting fluids. Comparative machining analyses&#xa0;were conducted between ICT and dry machining, evaluating parameters such as surface roughness, cutting forces, and tool wear mechanisms under different cutting conditions. Additionally, an evaluation was conducted using the Pugh matrix, considering 13 indicators applied to six different cooling-lubrication methods, aiming to identify the most efficient and sustainable solution. The results showed that the ICT system was effective in reducing cutting forces and improving surface roughness compared to dry machining. The analysis of tool wear mechanisms revealed the predominance of adhesion, followed by friction, abrasion, and a lower occurrence of plastic deformation. The sustainability evaluation performed using the Pugh matrix, highlighted ICT as a promising and environmentally friendly solution, outperforming conventional methods due to its superior heat dissipation capability. However, further studies are needed to explore and consolidate the benefits of this innovative approach.</p>

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Machining gray cast iron with internally cooled tools: performance, wear, and sustainability assessment

  • 期刊论文

  • 发表日期：

    2025年5月15日

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  • Augusto César Santos Peixoto,
  • Gustavo Henrique Nazareno Fernandes,
  • Paulo Sérgio Martins,
  • Lucas Melo Queiroz Barbosa,
  • Pedro Henrique Pires França,
  • Márcio Bacci da Silva,
  • Éder Silva Costa,
  • Vitor Baldin,
  • Washington Martins da Silva Jr.,
  • Álisson Rocha Machado

摘要

Gray cast iron (GCI/FC) is widely used in various industrial applications, especially in the automotive industry, such as in engine blocks and brake discs, where machining plays a crucial role in manufacturing these components. In modern machining, the proper selection of cutting parameters and cooling-lubrication methods is essential not only to reduce costs but also to ensure precise geometric tolerances, high-quality surface finish, and compliance with environmental and occupational health standards. To address the challenges associated with the use of conventional cutting fluids, which have negative impacts on the pillars of the triple bottom line (TBL)—economic, social, and environmental—this study proposed the development of an internally cooled tool (ICT) system. In this system, a cooling fluid circulates exclusively through the tool and tool holder, avoiding direct contact with the workpiece and the operator. This innovative approach contributed to reducing environmental impacts, minimizing health risks to the operator, and lowering the costs associated with the acquisition and disposal of cutting fluids. Comparative machining analyses were conducted between ICT and dry machining, evaluating parameters such as surface roughness, cutting forces, and tool wear mechanisms under different cutting conditions. Additionally, an evaluation was conducted using the Pugh matrix, considering 13 indicators applied to six different cooling-lubrication methods, aiming to identify the most efficient and sustainable solution. The results showed that the ICT system was effective in reducing cutting forces and improving surface roughness compared to dry machining. The analysis of tool wear mechanisms revealed the predominance of adhesion, followed by friction, abrasion, and a lower occurrence of plastic deformation. The sustainability evaluation performed using the Pugh matrix, highlighted ICT as a promising and environmentally friendly solution, outperforming conventional methods due to its superior heat dissipation capability. However, further studies are needed to explore and consolidate the benefits of this innovative approach.