Corporate Powerpoint
Senior Research Scientist MetalworkingYour Presenter : Dr.
Robert Evans
Over 39 years of experience in the research and development of
industrial metalworking lubricants and rust
[email protected] & Metalworking
Fluid Performance in the Machining of Ferrous Metal-Cast Aluminum
Bi-Metal Components
Welcome
2017 Quaker Chemical Corporation. All rights reserved.
1
Major global supplier of process fluids since the
1918Headquarters in Conshohocken, Pennsylvania USA36 Locations in
21 Countries2,040 Associates worldwideQuaker has over 4,500
customers including some of the largest, well-known automotive and
steel manufacturers in the worldStrong Financial Base Public NYSE
KWR
Sales +/- $750m
R&D Expenditures$22.1m
We are Quaker.
2017 Quaker Chemical Corporation. All rights reserved.Dana will
update if we can we get the new numbers in time2
A Global Partner
2017 Quaker Chemical Corporation. All rights reserved.
2017 Quaker Chemical Corporation. All rights reserved.
3
Major supplier of metalworking fluids to the automotive, heavy
equipment and related industriesTechnical centers with fully
instrumented machining centers at all global regionsSignificant
research effort committed to supporting the emerging trends in
automotive engine manufacturing
USA Technical Center
China Technical Center
S.A Technical CenterJapan Technical Center
Netherlands Technical CenterA Global Partner
2017 Quaker Chemical Corporation. All rights reserved.
4
Increased Fuel EfficiencyReduced EmissionsLighter weight to
engine and associated componentsStronger materials for engine and
associated componentsNew highly engineered materials and material
combinationsMachining Challenges
Trends
2017 Quaker Chemical Corporation. All rights reserved.
Case hardened hydroformed cam shafts Higher strength, wear
resistant valve seats Increased use of titanium & nickel based
alloys Use of high strength cast irons Use of bi-metallic
componentsExamples
2017 Quaker Chemical Corporation. All rights reserved.
6
What is Bi-Metal MachiningSimultaneous machining of two
dissimilar materials whereby one material serves to provide light
weighting, while the second fulfills a role requiring high
strength, and thermal resistance
2017 Quaker Chemical Corporation. All rights reserved.
Eg: Aluminum engine blocks lighter weight
Cast iron cylinder sleevesCast iron or powdered ferrous metal
bearing capsBi-Metal Machining in Engine ProductionCrankshaft Bore
ReamingDeck Facing of Engine Block2017 Quaker Chemical Corporation.
All rights reserved.
2017 Quaker Chemical Corporation. All rights reserved.
Differences in mechanical and thermal properties between the two
materials
Compromise on the machining conditions and tooling usedWhy are
bi-metal parts difficult to machine?
2017 Quaker Chemical Corporation. All rights reserved.
9
Ductile Cast IronFerrous Powdered MetalBi-Metal Crankshaft Bore
Aluminum-Silicon Cast AlloyDifferences in Mechanical & Thermal
Properties
2017 Quaker Chemical Corporation. All rights reserved.
10
Differences in Mechanical & Thermal Properties
m/mK (20-100C)
2017 Quaker Chemical Corporation. All rights reserved.
11
Large differences in friction properties between the two
metalsImpact on quality of reamed bore surface finish and bore
cylindricity
Elevated machining vibrations & cutting forcesDifferences in
Mechanical & Thermal Properties
2017 Quaker Chemical Corporation. All rights reserved.
12
Polycrystalline Diamond Best for aluminumIncompatible with
ferrous metals
CarbidesAccelerated wear from silicon in aluminumGood for
ferrous
Aluminum Higher is betterIron Lower is better
ToolingCompromise on Tooling & Machining ConditionsCutting
Speeds
2017 Quaker Chemical Corporation. All rights reserved.Please
clean up and correct colors 13
Compromise on Tooling & Machining Conditions
2017 Quaker Chemical Corporation. All rights reserved.
Machining Test CriterionEffectively simulates the actual
machining processReplicates the drop in machinability with bi-metal
boresStudying Crank Bore Reaming
2017 Quaker Chemical Corporation. All rights reserved.
15
FC 0208 Powdered Metal Aluminum 356-T6
Simulation of Crank Bore Reaming in Laboratory Machining
Tests
Aluminum Aluminum bore for baseline performancePearlite Ferrite
Porosity
2017 Quaker Chemical Corporation. All rights reserved.
16
15.87 mm dia. 6-fluted carbide reamer @ v = 30 m/min f = .152
mm/revBi-Metal Reaming Operation
2017 Quaker Chemical Corporation. All rights reserved.Bi-Metal
Reaming Operation
2017 Quaker Chemical Corporation. All rights reserved.
Machinability assessed via1. Reamed hole cylindricity 2. Reamed
surface roughness Bi-Metal Reaming Operation
2017 Quaker Chemical Corporation. All rights reserved.
19
Poor cylindricity gives rise to unstable hydrodynamic
lubrication conditions and potential points of metal-metal
contactImportance of Cylindricity & Finish
Operates in a hydrodynamic regime of lubrication
2017 Quaker Chemical Corporation. All rights reserved.
20
Importance of Cylindricity & FinishHigh roughness with the
bore surface will negatively affect heat transfer from the journal
bearings to the surrounding metals
2017 Quaker Chemical Corporation. All rights reserved.
21
Using a CMMCylindricity Results
2017 Quaker Chemical Corporation. All rights reserved.
22
Aluminum Surface Finish Results
Aluminum-Aluminum Part
Aluminum-Powdered Metal PartUsing a standard semi-synthetic
Aluminum machining fluidReamed aluminum surface from
Aluminum-Aluminum partReamed aluminum surface from Aluminum-PM
part
2017 Quaker Chemical Corporation. All rights reserved.
23
High level of lubrication to maintain constant friction and
stable cutting forces during continuously changing and alternating
cutting conditionsQUAKERCOOL 7450
Semi-synthetic metalworking fluid designed for aluminum &
bi-metal machiningProvides high lubrication on ferrous metals
without compromise or detriment to the aluminum machining
performance of the fluid
2017 Quaker Chemical Corporation. All rights
reserved.Cylindricity of Reamed Holes
2017 Quaker Chemical Corporation. All rights reserved.
Reamed Aluminum Surface Finish
2017 Quaker Chemical Corporation. All rights reserved.
26
Leaves machines cleanGood tramp oil rejectionConsistent
performance over a wide range of water/emulsion hardness
QUAKERCOOL 7450 Aluminum & Bi-Metal Machining Fluid
Experience Globally utilized by many automotive OEMs and Tier 1
& 2 manufacturers for the machining of aluminum engine blocks,
cylinder heads, and associated components (valve seats and guides,
steering components, fuel injectors etc.)Long sump life and low
consumption Provides Myco bacteria resistance & bio stability
against bacteria & fungi
2017 Quaker Chemical Corporation. All rights reserved.
27
Bi-metal machining presents significant challenges with regard
to machinability and the quality of the part produced
QUAKERCOOL 7450 - Metalworking fluid designed for effective
performance on both aluminum and ferrous metals - can offer
significant benefit in bi-metal machining operationsConclusions:
Bi-Metal Machining
2017 Quaker Chemical Corporation. All rights reserved.
28
Bi-Metal Machining Crank Bore ReamingTaylor Grimm, Ingvar
Jochumsson, Michael Hanlon, John OBrien
Department of Industrial & Manufacturing Engineering and
Department of Materials Science & Engineering
The Pennsylvania State UniversityAcknowledgements
2017 Quaker Chemical Corporation. All rights reserved.
29
30
Thank You Dr. Robert EvansSenior Research ScientistMetalworking
Research LaboratoryQuaker Chemical
[email protected]
2017 Quaker Chemical Corporation. All rights reserved.