Critical analysis of wear mechanisms in carbide tools applied in the machining of high-strength cast iron alloys

The development of high-strength cast iron alloys has become critical for advancing manufacturing processes, particularly in the automotive and heavy machinery sectors. Vermicular cast iron offers significant advantages in terms of mechanical properties and thermal conductivity, making it a valuable alternative to traditional gray cast iron. However, its machinability remains a major challenge due to increased tool wear. This study investigates the wear mechanisms of uncoated carbide tools during the front milling of four distinct cast iron alloys: FC250 gray cast iron, FC300 gray cast iron with molybdenum addition, gray cast iron with molybdenum addition and graphite refinement, and FV450 vermicular cast iron. The experiments were performed under dry cutting conditions, with varying cutting speeds (230 and 350 m/min) and feed rates (0.10 and 0.20 mm/tooth), to assess the influence of these parameters on tool wear. The results indicated that FV450 vermicular cast iron exhibited the highest wear rate, significantly reducing tool life compared to the other alloys. Scanning Electron Microscope—SEM analysis revealed predominant wear mechanisms such as attrition and abrasion. Also microchipping could be checked. The entire wear were exacerbated at higher cutting speeds and feed rates. Additionally, statistical analysis demonstrated that cutting speed is the most influential factor affecting tool wear, followed closely by feed rate, with the FV450 alloy showing the worst machinability due to its unique microstructure. These findings offer valuable insights for optimizing machining parameters in the processing of high-strength cast irons and contribute to the body of knowledge regarding the machinability challenges posed by vermicular cast iron.