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<p>Compacted graphite cast iron (CGI) is an ideal material for high-performance automotive components, but its widespread application is limited by poor machinability. The machining characteristics of CGI are closely related to its microstructure and accompanied by significant tool wear, necessitating a deeper understanding of how tool wear state and microstructural features affect the machining process. This study developed a microscopic finite element model incorporating vermicular graphite and pearlite phases. Numerical simulations and experimental investigations were conducted on cutting processes using two coated tools (Al₂O₃/TiCN and TiAlN) at different wear stages. The effects of microstructure, coating properties, and tool wear on chip morphology, cutting force, temperature distribution, and wear mechanisms were systematically analyzed. Results show that the maximum temperature concentrates in the crater wear region under both coating conditions (approximately 462&#xa0;°C for TiAlN and 464&#xa0;°C for Al₂O₃/TiCN), with high-temperature zones expanding continuously as wear progresses, thereby intensifying edge damage and plastic deformation. Stress analysis reveals that Al₂O₃/TiCN coating exhibits higher stress standard deviation and mean tensile stress than TiAlN coating across different wear stages and spatial scales, making it more susceptible to crack initiation and propagation at the coating/substrate interface. Good agreement between simulation results and experimental data validates the effectiveness of the proposed microscopic finite element model for studying CGI machining with worn tools.</p>

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Microscopic Numerical Simulation and Experimental Investigation on the Machining Process of Compacted Graphite Cast Iron (CGI) Considering Microstructure and Different Tool Wear States

  • 期刊论文

  • 发表日期：

    2026年4月21日

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  • Debin Lai,
  • Rongwen Huang,
  • Sen Li,
  • Jingru Zhang,
  • Qiyuan Deng,
  • Tianhao Deng,
  • Xiaoping Liao,
  • Yongchuan Lin

摘要

Compacted graphite cast iron (CGI) is an ideal material for high-performance automotive components, but its widespread application is limited by poor machinability. The machining characteristics of CGI are closely related to its microstructure and accompanied by significant tool wear, necessitating a deeper understanding of how tool wear state and microstructural features affect the machining process. This study developed a microscopic finite element model incorporating vermicular graphite and pearlite phases. Numerical simulations and experimental investigations were conducted on cutting processes using two coated tools (Al₂O₃/TiCN and TiAlN) at different wear stages. The effects of microstructure, coating properties, and tool wear on chip morphology, cutting force, temperature distribution, and wear mechanisms were systematically analyzed. Results show that the maximum temperature concentrates in the crater wear region under both coating conditions (approximately 462 °C for TiAlN and 464 °C for Al₂O₃/TiCN), with high-temperature zones expanding continuously as wear progresses, thereby intensifying edge damage and plastic deformation. Stress analysis reveals that Al₂O₃/TiCN coating exhibits higher stress standard deviation and mean tensile stress than TiAlN coating across different wear stages and spatial scales, making it more susceptible to crack initiation and propagation at the coating/substrate interface. Good agreement between simulation results and experimental data validates the effectiveness of the proposed microscopic finite element model for studying CGI machining with worn tools.