Effect of Chill Plate Thickness on Surface Hardening and Dimensional Accuracy of Nodular Cast Iron Gears Manufactured by the Chill Casting Method
The gear manufacturing method is an important determinant of their performance and service life. Surface hardness and dimensional accuracy play a significant influence in determining wear and contact fatigue in gears. This study’s goal was to measure the gear profile dimensions and surface behavior...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-04-01
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| Series: | Designs |
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| Online Access: | https://www.mdpi.com/2411-9660/7/2/56 |
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| author | Natalino Fonseca Da Silva Guterres Rusnaldy Rusnaldy Achmad Widodo |
| author_facet | Natalino Fonseca Da Silva Guterres Rusnaldy Rusnaldy Achmad Widodo |
| author_sort | Natalino Fonseca Da Silva Guterres |
| collection | DOAJ |
| description | The gear manufacturing method is an important determinant of their performance and service life. Surface hardness and dimensional accuracy play a significant influence in determining wear and contact fatigue in gears. This study’s goal was to measure the gear profile dimensions and surface behavior of nodular cast iron made using the chill casting technique. Chill plates made of 304 stainless steel with thicknesses of 0.2, 0.4, and 0.6 mm were used to provide good surface cooling rates during the chill casting of gears performed using open molds of silica sand. Chill plates are plated onto the walls of the mold, and then the molten material is poured at 1400 °C. The obtained gears were tested using photographs, microstructures, SEM-EDX, microhardness, wear, and dimensional measurements. The thickness of the chill plate can affect the hardening process of the gear surface. Thicker chill plates result in slower cooling rates, resulting in a more homogeneous microstructure and increasing the hardness level of the hardened layer. Whereas thinner chill plates result in a faster cooling rate, which results in a higher hardness and wear resistance of the hardened layer. Reducing the thickness of the chill plate from 0.6 mm to 0.2 mm increases the cooling rate and increases the amount of diffusion that can occur. The results showed that M<sub>7</sub>C<sub>3</sub> and the (FeCrC)<sub>7</sub>C<sub>3</sub> matrices were formed, with an average hardness within a range of 700–994.96 HV. A chill plate with a thickness of 0.4 mm produces gear with the best accuracy and precision. |
| first_indexed | 2024-03-11T05:05:43Z |
| format | Article |
| id | doaj.art-212c17e3be45452fb3b09bdaaec31dde |
| institution | Directory Open Access Journal |
| issn | 2411-9660 |
| language | English |
| last_indexed | 2024-03-11T05:05:43Z |
| publishDate | 2023-04-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Designs |
| spelling | doaj.art-212c17e3be45452fb3b09bdaaec31dde2023-11-17T18:54:03ZengMDPI AGDesigns2411-96602023-04-01725610.3390/designs7020056Effect of Chill Plate Thickness on Surface Hardening and Dimensional Accuracy of Nodular Cast Iron Gears Manufactured by the Chill Casting MethodNatalino Fonseca Da Silva Guterres0Rusnaldy Rusnaldy1Achmad Widodo2Department of Mechanical Engineering, Diponegoro University, Prof. Soedharto Street, Tembalang, Semarang 50275, IndonesiaDepartment of Mechanical Engineering, Diponegoro University, Prof. Soedharto Street, Tembalang, Semarang 50275, IndonesiaDepartment of Mechanical Engineering, Diponegoro University, Prof. Soedharto Street, Tembalang, Semarang 50275, IndonesiaThe gear manufacturing method is an important determinant of their performance and service life. Surface hardness and dimensional accuracy play a significant influence in determining wear and contact fatigue in gears. This study’s goal was to measure the gear profile dimensions and surface behavior of nodular cast iron made using the chill casting technique. Chill plates made of 304 stainless steel with thicknesses of 0.2, 0.4, and 0.6 mm were used to provide good surface cooling rates during the chill casting of gears performed using open molds of silica sand. Chill plates are plated onto the walls of the mold, and then the molten material is poured at 1400 °C. The obtained gears were tested using photographs, microstructures, SEM-EDX, microhardness, wear, and dimensional measurements. The thickness of the chill plate can affect the hardening process of the gear surface. Thicker chill plates result in slower cooling rates, resulting in a more homogeneous microstructure and increasing the hardness level of the hardened layer. Whereas thinner chill plates result in a faster cooling rate, which results in a higher hardness and wear resistance of the hardened layer. Reducing the thickness of the chill plate from 0.6 mm to 0.2 mm increases the cooling rate and increases the amount of diffusion that can occur. The results showed that M<sub>7</sub>C<sub>3</sub> and the (FeCrC)<sub>7</sub>C<sub>3</sub> matrices were formed, with an average hardness within a range of 700–994.96 HV. A chill plate with a thickness of 0.4 mm produces gear with the best accuracy and precision.https://www.mdpi.com/2411-9660/7/2/56ductile irongearschill castinghardnesswearmicrostructure |
| spellingShingle | Natalino Fonseca Da Silva Guterres Rusnaldy Rusnaldy Achmad Widodo Effect of Chill Plate Thickness on Surface Hardening and Dimensional Accuracy of Nodular Cast Iron Gears Manufactured by the Chill Casting Method Designs ductile iron gears chill casting hardness wear microstructure |
| title | Effect of Chill Plate Thickness on Surface Hardening and Dimensional Accuracy of Nodular Cast Iron Gears Manufactured by the Chill Casting Method |
| title_full | Effect of Chill Plate Thickness on Surface Hardening and Dimensional Accuracy of Nodular Cast Iron Gears Manufactured by the Chill Casting Method |
| title_fullStr | Effect of Chill Plate Thickness on Surface Hardening and Dimensional Accuracy of Nodular Cast Iron Gears Manufactured by the Chill Casting Method |
| title_full_unstemmed | Effect of Chill Plate Thickness on Surface Hardening and Dimensional Accuracy of Nodular Cast Iron Gears Manufactured by the Chill Casting Method |
| title_short | Effect of Chill Plate Thickness on Surface Hardening and Dimensional Accuracy of Nodular Cast Iron Gears Manufactured by the Chill Casting Method |
| title_sort | effect of chill plate thickness on surface hardening and dimensional accuracy of nodular cast iron gears manufactured by the chill casting method |
| topic | ductile iron gears chill casting hardness wear microstructure |
| url | https://www.mdpi.com/2411-9660/7/2/56 |
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