An Experimental Study on Nodular Iron Machined Surfaces Utilizing a Capable 2D Finite Element Model for Precise Surface Roughness Estimation

Abstract

Nodular iron plays a crucial role in various industries, especially in large-scale applications such as gearboxes. Ensuring that nodular iron remains free from oil leakage and that contact surfaces are properly aligned is essential, given its operational requirements. Achieving flat contact faces through precise machining is therefore of utmost importance. As surface roughness and flatness are closely linked, it is vital to investigate the machining process parameters involved. This study focuses on addressing surface quality issues with EN-GJS-600-3 cast iron by optimizing machining parameters. CMM measurements were utilized to analyze the relationship between surface roughness and flatness, with a surface profile used to assess flatness. Furthermore, a new 2D surface roughness estimation method (2D-SRET) was created and tested with experimental data in order to improve the precision of assessing the discrete flat surface machining procedure.