Correlative approach towards integrated casting-heat treatment route and machining for sustainable ADI manufacturing

Abstract : The environmental impacts of material production and processing are rapidly increasing and critical. These impacts can be reduced, to some extent, by development of either a suitable material or by implementing a novel process route to improve the material efficiency. In such circumstances, the recent emergence of near-net shape austempered ductile iron (ADI) can be considered as a significant economic advantage to the increasing industrial demand of cost and weight efficient materials. The present study is thus dedicated to the development of an innovative methodology for austempered ductile iron (ADI) manufacturing considering all production aspects such as melt treatment, casting, heat treatment and machining. The innovative process design advances the integrated approach towards casting and heat treatment practices for ADI production in a permanent mould. It is based on the fundamental correlation between the production conditions and its combined influences on the microstructure and mechanical properties of ADI. Moreover, the present study introduces a correlative thermal methodology approach to understand the castability of ductile iron in a permanent mould for ADI production. The simulation tool correlates the combined influences of thermal characteristics, heat transfer at melt/mould interface, and melt's castability on the final casting quality. Finally, the ecological machining of ADI is introduced by implementing the dry and MQL machining process. The key aspect of the novel ADI machinability was investigated with respect to its microstructural characteristics, tool wear mechanisms, chip formation characteristics and the machined surface's quality. The combined correlative approaches provide the key findings aim to (i) understand the influence of microstructural characteristics of novel ADI on its mechanical properties, (ii) demonstrate the influence of thermal characteristics of melt on the castability of ductile iron in a permanent mould, and (iii) correlating the machining characteristics of ADI with its microstructure and production conditions.
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Anil Meena. Correlative approach towards integrated casting-heat treatment route and machining for sustainable ADI manufacturing. Mechanical engineering [physics.class-ph]. Arts et Métiers ParisTech, 2012. English. ⟨NNT : 2012ENAM0026⟩. ⟨pastel-00790193⟩

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