Form deviation in machining of spheroidal cast iron and aluminum compounds.

Turning of metallic compounds in comparison to single materials leads to unfavourable changes of the workpiece quality. Form and shape deviations as well as surface quality degradations occur when different materials are machined alternately in one cutting operation. This is due to different material properties, cutting characteristics, chip formation mechanisms as well as characteristic interactions between the single components. A compromise of the process design, for instance adjustment of the cutting tool and process parameters, can increase the workpiece quality to a large extent. This paper deals with the optimization of cutting processes for the machining of compounds consisting of typical materials used in an automobile engine block. The focus is on the workpiece quality which can be evaluated by the radius deviation, transition deviation as well as the surface roughness and surface roughness difference. The results display that the best workpiece quality can be achieved in a high speed cutting process.