An analysis of the machinability of ASTM grades 2 and 3 austempered ductile iron

The main goal of this work is to perform an analysis of the machinability of two ASTM grades of ADI, namely 2 and 3. The samples used in this work were cast and austempered according to ASTM standards for the production of grade 2 (G2) and grade 3 (G3) ADI. Characterization was accomplished through tensile and hardness tests, metallography and X-ray diffraction. Machinability was evaluated by analyzing tool life, cutting forces, surface finish and chip characteristics in turning operations. A quick-stop test was also performed in order to verify some mechanical processes during the chip formation and to analyze the shear plane angle. Tool life when machining G2 was 33% lower than G3 (18 min against 26 min), although the latter is a harder material. Abrasion and adhesion were the wear mechanisms observed through SEM images, whereas in other cast irons mainly abrasion is observed. Cutting forces measurements showed that the value of Kc1,1 decreased 19%, from 1448 to 1175 N/mm2, for G2 as the depth of cut increased from 2 to 5 mm at a cutting speed of 80 m/min and 18%, from 1501 to 1236 N/mm2, for G3. Surface roughness measurements proved that a smoother surface is obtained for both alloys at f = 0.10 mm/rev when using an insert with nose radius 1.6 mm instead of smaller radii. Both alloys presented similar surface quality. All chips observed were segmented.