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<p>Austempered ductile iron (ADI) results from heat treatment carried out under isothermal conditions called austempering. Subjecting nodular cast iron to this treatment improves its mechanical properties, such as increased ductility and mechanical resistance. Although these properties are beneficial and desired in many cases, ADI is considered a difficult material to machine due to its inherent microstructure-induced properties. Thermal and mechanical effects are generated during the ADI milling process, which can alter its microstructure and residual stress state. This work evaluated end milling conditions effects in ADI grade 3 machined surfaces with magnetic Barkhausen noise (MBN) and x-ray diffraction tensometry. The milled was performed with uncoated carbide tools in the 3-axis machining center, varying cutting speed at 120 and 160&#xa0;m/min, depth of cut 1 and 0.37&#xa0;mm, and fluid application (dry and jet). Were analyzed roughness, MBN, and residual stress. Test results showed that increased cutting speed deteriorates the surface quality and leads to a more tensile residual stress. The increase in depth of cut contributed to a decrease in the MBN. Due to the environmental and economic impact, dry conditions with low cutting speed and high depth of cut are more suitable for ADI end milling.</p>

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Evaluation of Austempered Ductile Iron End Milling by Magnetic Barkhausen Noise and x-Ray Diffraction Methods

  • 期刊论文

  • 发表日期：

    2025年2月18日

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  • Lucas Benini,
  • Pedro Paulo Rosa de Paula,
  • Sérgio Souto Maior Tavares,
  • Felipe de Sá Carnerio,
  • Leosdan Figueredo Noris,
  • Bruna Machado da Conceição,
  • José Mauro Moraes Júnior

摘要

Austempered ductile iron (ADI) results from heat treatment carried out under isothermal conditions called austempering. Subjecting nodular cast iron to this treatment improves its mechanical properties, such as increased ductility and mechanical resistance. Although these properties are beneficial and desired in many cases, ADI is considered a difficult material to machine due to its inherent microstructure-induced properties. Thermal and mechanical effects are generated during the ADI milling process, which can alter its microstructure and residual stress state. This work evaluated end milling conditions effects in ADI grade 3 machined surfaces with magnetic Barkhausen noise (MBN) and x-ray diffraction tensometry. The milled was performed with uncoated carbide tools in the 3-axis machining center, varying cutting speed at 120 and 160 m/min, depth of cut 1 and 0.37 mm, and fluid application (dry and jet). Were analyzed roughness, MBN, and residual stress. Test results showed that increased cutting speed deteriorates the surface quality and leads to a more tensile residual stress. The increase in depth of cut contributed to a decrease in the MBN. Due to the environmental and economic impact, dry conditions with low cutting speed and high depth of cut are more suitable for ADI end milling.