Lubrication & Metalworking Fluid Performance in the Machining of Ferrous Metal-Cast Aluminum Bi-Metal Components

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

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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.

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A Global Partner



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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


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Increased Fuel EfficiencyReduced EmissionsLighter weight to engine and associated componentsStronger materials for engine and associated componentsNew highly engineered materials and material combinationsMachining Challenges

Trends


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


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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


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.


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?


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Ductile Cast IronFerrous Powdered MetalBi-Metal Crankshaft Bore Aluminum-Silicon Cast AlloyDifferences in Mechanical & Thermal Properties


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Differences in Mechanical & Thermal Properties

m/mK (20-100C)


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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


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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

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Compromise on Tooling & Machining Conditions


Machining Test CriterionEffectively simulates the actual machining processReplicates the drop in machinability with bi-metal boresStudying Crank Bore Reaming


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FC 0208 Powdered Metal Aluminum 356-T6

Simulation of Crank Bore Reaming in Laboratory Machining Tests

Aluminum Aluminum bore for baseline performancePearlite Ferrite Porosity


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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


Machinability assessed via1. Reamed hole cylindricity 2. Reamed surface roughness Bi-Metal Reaming Operation


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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


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Importance of Cylindricity & FinishHigh roughness with the bore surface will negatively affect heat transfer from the journal bearings to the surrounding metals


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Using a CMMCylindricity Results


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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


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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


Reamed Aluminum Surface Finish


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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


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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


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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


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Thank You Dr. Robert EvansSenior Research ScientistMetalworking Research LaboratoryQuaker Chemical [email protected]


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Lubrication & Metalworking Fluid Performance in the Machining of Ferrous Metal-Cast Aluminum Bi-Metal Components