This paper studies causes of scrap occurrence, wear and breakage of cutters during thread cutting of steel sleeves poured in Al die castings of motor car engine components. It was concluded that the reason for occurrence of problems with thread cutting of sleeves most probably should be attributed to the fact whether hardness value reaches 200 HB or over 250 HB. The most probable reason for over wear and consequently to breakage of cutters and scrap occurrence, although castings display top quality, lies in the fact that the internal diameter of sleeves frequently falls down under minimally allowed tolerances for threaded sleeves

I. Budić

T. Šarić

V. Marušić

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METALURGIJA 46 (2007) 2, 135-139 135V. Marušić et al.: INVESTIGATOION OF CAUSES OF SCRAP OCCURRENCE IN THREAD CUTTING ON ...Received - Primljeno: 2006-03-08accepted - Prihvaćeno: 2006-09-25Professional Paper - Strukovni radISSN 0543-5846METABK 46 (2) 135-139 (2007)UDC - UDK 669.716:621.74=111 rušić, i. Budić, T. šarićV. Marušić, i. Budić, T. šarić, Faculty of Mechanical Engineering uni-versity of Osijek, Slavonski Brod, CroatiaINVESTIGATION OF CAUSES OF SCRAP OCCURRENCE IN THREAD CUTTING ON STEEL SLEEVES FOR MOTORCAR INDUSTRYINTRODUCTIONNonconforming, and for their purpose unusable cast-ings, not fulfilling the requirements of the standard and/or with customer agreed delivery conditions represent scrap [1, 2]. Scrap is manifested in foundries as waste in material, energy and labor. its efficient monitoring and supervision is possible only when the quality criteria have been unequiv-ocally established, not only for the final product but also for single operations. Taking into account harsh market competition, only top quality product can be sold, and that at prices acceptable to customer. Scrap can significantly influence the profitability of production. Therefore, it is of the utmost importance, that causes of scrap occurrence are discovered as soon as possible. The biggest waste is when scrap occurs in final stage of casting production.Steel sleeves for carriers of motor components in car industry have been taken as an example of unforeseen increase in production cost. during the process of die casting of aluminum carriers, steel sleeves have been cast into them, and additionally threads have been cut. it was This paper studies causes of scrap occurrence, wear and breakage of cutters during thread cutting of steel sleeves poured in Al die castings of motor car engine components. It was concluded that the reason for occur-rence of problems with thread cutting of sleeves most probably should be attributed to the fact whether hardness value reaches 200 HB or over 250 HB. The most probable reason for over wear and consequently to breakage of cutters and scrap occurrence, although castings display top quality, lies in the fact that the internal diameter of sleeves frequently falls down under minimally allowed tolerances for threaded sleeves. Key words: Al die casting, carriers, cutting of threads, sleeves, scrapIstraživanje uzroka nastajanju škarta pri urezivanju navoja u čelične umetke tlačno lijevanih Al nosača dijelova motora. U radu je istraživan uzrok nastajanju škarta, trošenja i lomljenja ureznika pri urezivanju navoja u čelične umetke “čahure” koji su zaliveni u aluminijskim tlačnim odljevcima nosača dijelova motora automobila. Zaključeno je da se  razlog problemu s urezivanjem navoja u čahure najvjerojatnije ne nalazi u tome da li je njihova tvrdoća ispod 200HB ili je preko 250HB. Vjerojatni razlog prekomjernom trošenju pa i lomu ureznika te nastajanju škarta, i pored toga što su nosači kvalitetno odliveni, je taj što se unutarnji promjer čahura često nalazi ispod minimalno propisanog za urezivani navoj.Ključne riječi: Al tlačni lijev, nosači, urezivanje navoja, čahure, škartobserved that cutters not only showed an unexpected wear but they frequently broke during threading. Consequently, there was increase in costs and price of the casting, and top quality castings turned frequently into scrap.EXPERIMENTAL WORKFor the purpose of research of causes of scrap occur-rence 5 castings have been taken by random sampling prior to thread cutting, and 5 raw steel sleeves in as delivered condition. These castings were used for testing of chemi-cal composition, microstructure, hardness values and di-mensional control to establish causes of waste occurrence during sleeve thread cutting.PROPERTIES OF DIE CASTED Al CARRIERSMotor carriers are manufactured by the process of die casting of al alloy alSi9Cu3(Fe)L226 obtained from secondary aluminum. Thereby, the melt at the temperature of 720 °C is poured around two steel sleeves, cooled with oil emulsion to ~ 300 °C, and afterwards cooled at air tem-perature. The entire process is automated. The appearance of the carrier is shown in Figure 1.METALURGIJA 46 (2007) 2, 135-139136V. Marušić et al.: INVESTIGATOION OF CAUSES OF SCRAP OCCURRENCE IN THREAD CUTTING ON ...although foundries carry out regular control of che-mical composition, an independent laboratory analyzed samples of one of the five motor carriers.Test results are shown in Table 1., where it can be ob-served that chemical composition corresponds approximate-ly to that declared for the alloy alSi9Cu3(Fe)L-226 [3].it can be observed that the mechanical properties of die cast al carriers lie within the boundaries set for AlSi9Cu3(Fe)L-226 [3].The declared material of sleeves is the steel C45 (accord-ing to EN 10083-1) [5]. From results obtained by chemical analyses (Table 3.) it can be observed that composition of sleeves corresponds to the standard requirements.according to [5] as delivered annealed steel (C45E+A) must have hardness value of maximum 207 HB, and in normalized condition (C45E+S) this value reaches max. 255 HB.Hardness value control HB 2/120/15 (F/D2 = 30) was carried out on poured steel sleeves, at the front side, and on the cut casting (sample for metallographic examination). Figure 2. shows the characteristic cross section mi-crostructure of al casting. it should be noticed that the microstructure corresponds to the customer contract provisions, whereby smaller irregularities in the form of internal gas holes and small inclusions of impurities [4] can also be observed.Two probe specimens for static tensile testing and hard-ness control were prepared from al carriers. The results are shown in Table 2.METALURGIJA 46 (2007) 2, 135-139 137V. Marušić et al.: INVESTIGATOION OF CAUSES OF SCRAP OCCURRENCE IN THREAD CUTTING ON ...The measured hardness values range from 250 to 270 HB. it was not observed that point of measurement affected the measured values.Metallographic examination on the cross section of steel sleeves (Figure 3.a) was carried out. The microstructure is rather homogenous ferrite - pearlite structure, typical for a normalized steel and no significant differences between the central and marginally located areas of al (Figure 3.b) could be observed.The control of cylindrical bores has been carried out on all 5 carriers, parallelism of axes, perpendicularity of sym-metry lines (on the surface of al casting) and span between symmetry lines of the sleeves. The control was performed on 3D device MERLIN 1100 TWIN STAR (Frerranti In-ternational), and results are shown in Table 4. The diameter of the sleeve bore (and cylindricality) have been controlled at two points: 1 = d1, at depth of 8 mm, 2 = d2 on 25 mm depth. Typical properties of the casting, those which define correctness of the carrier for installation into motor vehicle, are shown in Figure 4.The results given in Table 4. indicate that parallel-ism, perpendicularity and symmetry line axes span of the sleeves lie within the frame specified in the technical documentation.Much more important is to notice that three sleeves out of tested five carriers (i.e. ten sleeves) showed lesser diameter then the minimally allowed of 16, 35 mm.CONTROL OF DAMAGED CUTTERSSeveral different cutters were examined for the purpose of control of the present damages. Besides their geometry, the cutters differ also by composition of their surface protec-tive coating on base material (HSS steel). This protective coating is with some cutters titan nitride (TiN) and with other titan carbide (TiC). The appearance of damaged cutters is shown on photo in Figure 5.Figure 6. shows characteristic appearance of the cracked surfaces of the cutter (broken during thread cutting).METALURGIJA 46 (2007) 2, 135-139138V. Marušić et al.: INVESTIGATOION OF CAUSES OF SCRAP OCCURRENCE IN THREAD CUTTING ON ...ried out as well as hardness measurement HB. results of testing of sleeves prior and after simulated heat treatment are shown in Table 5.The detailed control of cracked surfaces of the broken cutters showed that:- the cutters broke under and angle of 45°,- local wrinkling of base material due to stresses over boundary of base metal tensile strength occurred,- some cutters changed color (“turned blue”) due to over-heating prior to breakage.TESTING OF RAW CLAMP SLEEVES The appearance of the not poured clamp sleeve is shown in Figure 7.a. 3d dimension control was carried out on all five raw, as delivered, clamp sleeves as well as hardness measurement HB 2/120/15 (due to small wall thickness Φ2 mm ball was used). after that, all sleeves were submit-ted to short time heating in electric furnace as to simulate conditions of heat treatment when pouring the melted al alloy. The furnace was heated to 720 °C (temperature was additionally controlled by thermocouple NiCrNi and moni-tored on Honeywell device). after that the sleeves were put into furnace, held for a minute, taken out and cooled in oil to 300 °C, followed by cooling to room temperature. after sleeves cleaning, repeated 3d dimension control was car-Out of results of dimensional control it can be observed that after short time “annealing” three out of five clamp sleeves showed a reduction of the internal diameter, while the other two displayed an increase (measured differences range up to maximum 0,008 mm). it must be pointed out that these are values within measured cylindricality of the bores. Only slight decrease of hardness value has been observed, from 260 - 270 HB to ~ 230 - 260 HB. However it must be pointed out that with one of the sleeves (No. 5) bore diameter in as delivered status was lesser then minimally allowed.The analysis of microstructure of cross section of as delivered sleeves was performed, after the simulated annealing treatment. in both cases characteristic for the ferite - pearlite microstructure could be observed the relatively small grain size and a significant difference between marginal areas and the central cross section area could not be noticed. The microstructure of these sleeves is shown in Figure 7.b.METALURGIJA 46 (2007) 2, 135-139 139V. Marušić et al.: INVESTIGATOION OF CAUSES OF SCRAP OCCURRENCE IN THREAD CUTTING ON ...REFERENCES [1] Norma ISO 9001:2000. [2] S. Hasse, Pogrješke na odljevcima (preveli s engl. prof. dunja Palijan i mr. sc. Mile Galić), Hrvatsko udruženje za ljevarstvo, Zagreb, 2003. [3] Norma EN 1706 AC 46100 (UNI 5076). [4] international atlas of Casting defects aFS, des Plaines, uSa, 1974. [5] Norma EN 10083-1, Vergütungsstähle, CEN, 1991. [6] B. Kraut: Strojarski priručnik, Tehnička knjiga, Zagreb, 1986. [7] d. Krumes, Toplinska obradba, Sveučilište Josipa Jurja Strossma-yera u Osijeku Strojarski fakultet u Slavonskom Brodu, Slavonski Brod, 2000.RESULT ANALYSISit must be noticed that no significant change of mi-crostructure at the cross section of sleeves in as delivered status as well as after simulated short time heat treatment in electric furnace for 1 minute has been established. To come to structural changes in steel heated at about al temperature, it is necessary to keep such temperature for a corresponding period of time [6]. Therefore, it is un-derstandable that the simulated heat treatment didn’t lead to significant changes of microstructure, and changes of sleeve hardness value (Table 5.), consequently the same did not occur also at the pouring of al carriers. Hardness values of such poured, raw, and shortly heat treated sleeves ranges between 230 and 270 HB. dimensional 3d control of al carries indicate to the following:- perpendicularity of sleeve symmetry lines with all 5 cast-ings lies within the boundaries of allowed tolerances,- sleeve bore span with all 5 castings is within the bound-aries of allowed tolerances,- measured diameters of sleeve bores with 3 out of 10 controlled bores is smaller then the minimally allowed for cutting of threads M18 × 1,5 mm.Out of results of dimensional control of sleeve bore it may be concluded that short time “annealing” does not affect the  internal diameter (because the measured differ-ences range at most up to 0,008 mm, which are the values within range of those measured cylindricality of the bores). Thereby, the sleeves show only an insignificant reduction of hardness values from 260 - 270 HB to 230 - 260 HB. it is important to notice that with four out of 5 raw sleeves the smallest internal diameter is greater then allowed (Φ 16,35 mm for cutting of threads M18 × 1,5 mm), whereby differences lie up to almost 0,1 mm (sleeve No. 1 and sleeve No. 2). it should be noticed that one of the sleeves (No. 5) shows already in as delivered status bore diameter lesser then minimally allowed.CONCLUSIONBased on 3d control in 5 of al carriers with clamp sleeves the following can be established:- bore diameter measured with 3 out of 10 sleeves is lesser then that allowed for the cutting of threads M18×1,5 mm,- al alloy fulfills approved norm requirements by its che-mical composition and mechanical properties,- geometrical properties of al carriers lies within range of requirements contained in technical documentation.With raw “as delivered” sleeves submitted additionally to “annealing” at 720 °C so as to simulate pouring conditions of al carriers, it is important to observe the following:- no significant reduction of bore diameter has been ob-served, as consequence of short time “annealing”;- three out of five sleeves had greater initial bore diameter for 0,05 to 0,1 mm then the minimally allowed for cut-ting of threads M18 x 1,5 mm. in one case this bore was “only” ~ 0,02 mm greater then minimally allowed 16,35 mm. But with one of the sleeves measured diameter was smaller then that minimally allowed;- with all sleeves with hardness value of ~ 270 HB in “as delivered” status, after simulated treatment in the furnace there was only insignificant reduction (from ~ 230 - 269 HB).Based upon the inspection of delivered cutters (Figure 3.a and 3.b) it can be seen they broke (cutters 1.1; 2.1; 2.2), while the others displayed only signs of “wear” (cutters 1.2; 1,3; 1,4). discoloration of some of the cutters caused (“turned blue”), by the overheating during thread cutting. The following can be concluded:- because 3d control established satisfactory perpendicular-ity of symmetry lines of the sleeve, it is not to be expected that damaging of cutters came as result of deviation of coaxial hole;- due to fact that cutters with surface coating TiN and TiC on HSS steel display breakage and material wear, coating itself does not affect essentially to cutter breakage.Many of the reasons for cutter damage lie in the fact that the bore of the sleeve poses a problem of grind “drain-age” during thread cutting. However, taking into account the extremely hard surface layer (TiN and TiC) on HSS steel, hardness of sleeves should not represent main reason for cutter breakage (which as a rule is the cause of  scrap occurrence also with well poured Al carriers).Cutter wear is in partly consequence of grind “drain-age”, but real cause of breakage with those sleeves which had smaller internal diameter then minimally allowed lies prevalently in overstress (stress above tensile strength of material), because the cutter not only enters the sleeve by cutting, it also shapes it by process of “rolling”.

Investigation of Causes of Scrap Occurrence in Thread Cutting on Steel Sleeves for Motorcar Industry

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