US20110041960A1 - High rigidity, high damping capacity cast iron - Google Patents

High rigidity, high damping capacity cast iron Download PDF

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Publication number
US20110041960A1
US20110041960A1 US12/940,140 US94014010A US2011041960A1 US 20110041960 A1 US20110041960 A1 US 20110041960A1 US 94014010 A US94014010 A US 94014010A US 2011041960 A1 US2011041960 A1 US 2011041960A1
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Prior art keywords
cast iron
damping capacity
modulus
young
content
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Abandoned
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US12/940,140
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English (en)
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Sakae Takahashi
Ryousuke Fujimoto
Naoki Sakamoto
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Shibaura Machine Co Ltd
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Toshiba Machine Co Ltd
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Assigned to TOSHIBA KIKAI KABUSHIKI KAISHA reassignment TOSHIBA KIKAI KABUSHIKI KAISHA ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FUJIMOTO, RYOUSUKE, SAKAMOTO, NAOKI, TAKAHASHI, SAKAE
Publication of US20110041960A1 publication Critical patent/US20110041960A1/en
Priority to US14/015,760 priority Critical patent/US20140000832A1/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C37/00—Cast-iron alloys
    • C22C37/10—Cast-iron alloys containing aluminium or silicon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/06—Special casting characterised by the nature of the product by its physical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/20—Measures not previously mentioned for influencing the grain structure or texture; Selection of compositions therefor
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D5/00—Heat treatments of cast-iron
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D6/00—Heat treatment of ferrous alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/08—Making cast-iron alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C37/00—Cast-iron alloys

Definitions

  • the present invention relates to high rigidity, high damping capacity cast iron having a high Young's modulus and high vibration damping capacity.
  • the cast iron of the present invention is used as a structural material for machine tools and high-precision machine tools required to have rigidity or for precise measurement instruments in which Young's modulus and vibration are matters of concern. Such use makes it possible to increase the machining efficiency of the material, and the accuracy and precision of the work.
  • flaky graphite cast iron which is relatively high in vibration damping capacity, has been mainly used as a structural material for machine tools.
  • Flaky graphite cast iron contains a large amount of flaky graphite and therefore has a complex-type vibration damping mechanism. Therefore, it has higher damping capacity than steel or the like and has advantageous characteristics in terms of formability and cost for manufacture of large structural materials.
  • other materials having a high damping capacity such as concrete-based materials, natural granite, and CFRP, for use as structural materials for machine tools in place of flaky graphite cast iron.
  • none of these materials have been actually used due to low rigidity, a problem with formability or cost, or the like.
  • flaky graphite cast iron is widely used as a structural material for machine tool beds, tables, columns, and the like, since it is advantageous in terms of damping properties, castability and cost.
  • machine tools for machining hard-to-work materials which are severely work-hardened, are required to have high rigidity such that large cutting can be stably maintained and to have a high damping capacity such that harmful vibration can be prevented. Therefore, in some cases where much higher vibration-damping capacity is desired, conventional flaky graphite cast iron cannot achieve sufficient machining efficiency or sufficient work accuracy due to the influence of vibration.
  • flaky graphite cast iron used for machine tools and the like such as FC 300
  • FC 300 contains a large amount of flaky graphite, which produces a complex-type damping mechanism.
  • the vibration damping capacity of such flaky graphite cast iron can be improved by increasing the amount of flaky graphite.
  • Young's modulus hereinafter simply referred to as Young's modulus
  • the graphite content of flaky graphite cast iron can be controlled by controlling the amounts of C and Si. If a structural material for machine tools has a low Young's modulus, the structural material must be made thick so that a certain level of rigidity can be maintained. This is not preferred, because of not only a problem with structural design but also an increase in cost.
  • Patent Documents 1, 2, and 3 disclose methods for improving the vibration damping capacity.
  • Patent Documents 1 to 3 all disclose a method for improving the logarithmic decrement.
  • Patent Documents 1 to 3 show the results of measurement of vibration damping capacity. However, nothing about Young's modulus is described in these documents, and the value of Young's modulus is unknown from the documents. Specifically, Patent Documents 1 and 2 relate to brake materials, and therefore, it is considered that in these documents, Young's modulus is not indispensable, but the strength is rather important. Particularly, Patent Document 1 discloses that an object of its invention is to provide a brake material having strength as high as that of gray cast iron and having damping capacity equal to or higher than that of gray cast iron. Patent Document 3 discloses that aluminum-containing, damping cast iron for improving damping performance has been invented in view of an improvement in the damping performance of machine tools or precision machining equipment. However, although for the purpose of maintaining the machine accuracy, it is indispensable to maintain the rigidity of the structural material, the document discloses nothing about it.
  • Patent Document 1 Jpn. Pat. Appln. KOKAI Publication No. 63-140064
  • Patent Document 3 Jpn. Pat. Appln. KOKAI Publication No. 2002-348634
  • a high rigidity, high damping capacity cast iron consists of a cast iron containing 3 to 7% of Al. And the cast iron is produced by heating at 280 to 630° C. after casting, and then cooling.
  • FIG. 1 is a characteristic chart illustrating the relationship between heat treatment temperature and damping performance improvement ratio.
  • FIG. 2 is a characteristic chart showing the relationship between Young's modulus and the logarithmic decrement of Al-containing flaky graphite cast iron.
  • FIG. 3 is a characteristic chart showing the relationship between Young's modulus and the logarithmic decrement of Al and Sn-containing flaky graphite cast iron.
  • An object of the present invention is to provide high-rigidity, high-damping-capacity cast iron whose vibration damping capacity is further improved with compatibility between Young's modulus and vibration damping capacity, which has been an issue in the prior art, and which thus has a high level of Young's modulus and vibration damping capacity.
  • an object of the present invention is to provide high-rigidity, high-damping-capacity cast iron that has the same level of Young's modulus as that of conventional flaky graphite cast iron, which is high in vibration damping capacity, and also has significantly high vibration damping capacity.
  • a high rigidity, high damping capacity cast iron according to the present invention is a cast iron containing 3 to 7% of Al and produced by heating at 280 to 630° C. after casting, and then cooling. More specifically, the first invention is a cast iron comprising 3 to 7% of Al, 0.25 to 1.0% of Mn, 0.04% or less of P, 0.03% or less of S, and the balance of Fe and inevitable impurities, and being produced by heating at 280 to 630° C. after casting, and then cooling.
  • a high rigidity, high damping capacity cast iron according to the present invention is a cast iron containing 3 to 7% of Al and 0.03 to 0.20% of Sn and produced by heating at 280 to 630° C. after casting, and then cooling. More specifically, the second invention is a cast iron comprising 3 to 7% of Al, 0.25 to 1.0% of Mn, 0.04% or less of P, 0.03% or less of S, 0.03 to 0.20% of Sn, and the balance of Fe and inevitable impurities, and being produced by heating at 280 to 630° C. after casting, and then cooling.
  • a high rigidity, high damping capacity cast iron according to the present invention is a cast iron containing 3 to 7% of Al, and C and Si in such amounts that a carbon equivalent represented by formula (1) below is from 3.30 to 3.95, and being produced by heating at 280 to 630° C. after casting, and then cooling.
  • Carbon equivalent (%) C content (%)+(1 ⁇ 3) ⁇ Si content (%) (1)
  • the third invention is a cast iron consisting of C and Si in such amounts that the carbon equivalent represented by formula (1) above is from 3.30 to 3.95, 3 to 7% of Al, 0.25 to 1.0% of Mn, 0.04% or less of P, 0.03% of less of S, 0.03 to 0.20% of Sn, and the balance of Fe and inevitable impurities, and being produced by heating at 280 to 630° C. after casting, and cooling.
  • a high-rigidity, high-damping-capacity cast iron whose vibration damping capacity is further improved with compatibility between Young's modulus and vibration damping capacity, and which thus has a high level of Young's modulus and vibration damping capacity. More specifically, there is provided a high-rigidity, high-damping-capacity cast iron that has the same level of Young's modulus as that of conventional flaky graphite cast iron, which is high in vibration damping capacity, and also has significantly high vibration damping capacity.
  • the vibration damping capacity of flaky graphite cast iron improves but reaches a limit.
  • the vibration damping capacity and Young's modulus are measured as the Al content is gradually increased, improvements of them are observed from an Al content of 3%, but the vibration damping capacity rather becomes lower as the Al content becomes higher than 7%.
  • the inventors have found that the addition of tin (Sn) to the Al-containing flaky graphite cast iron improves Young's modulus and the vibration damping capacity.
  • the inventors have revealed that the vibration damping capacity and Young's modulus can be significantly changed by controlling the carbon equivalent (C.E.), the C/Si weight ratio, the Al content, and the Sn content of flaky graphite cast iron.
  • C.E. carbon equivalent
  • the C.E., the C/Si weight ratio, the Al content, and the Sn content described in claims should be adequately controlled.
  • the Al content is defined to be from 3 to 7% for the reasons described below. From 3%, the Al content starts to have an advantageous effect on the vibration damping capacity of Al and Sn-containing flaky graphite cast iron. If the Al content is less than 3%, almost no improvement effect can be observed. If it becomes 6% or more, the vibration damping capacity may gradually decrease, and if it exceeds 7%, the vibration damping capacity may further decrease. If the Al content is more than 7%, iron aluminum carbide formed by the addition of Al becomes hard and brittle, so that the material becomes fragile and less workable. For the reasons described above, the adequate Al content is set at 3 to 7%.
  • the Sn content is defined to be from 0.03 to 0.2% for the reasons described below. If the Sn content is too low, the effect of improving Young's modulus and the vibration damping capacity cannot be observed. From about 0.03%, the content becomes effective in improving Young's modulus and the vibration damping capacity, and when the content is around 0.08%, the effect becomes most significant. As the Sn content increases, the effect gradually decreases, and when the content becomes 0.2% or more, the effect significantly decreases, so that the improvement effect cannot be obtained. Thus, the adequate Sn content is from 0.03 to 0.2%. Sn is an important additive element, because it can improve not only Young's modulus and the vibration damping capacity but also the tensile strength.
  • the high rigidity, high damping capacity cast iron of the invention contains elements other than Al and Sn, such as C, Si, Mn, P, and S.
  • the C content and the Si content are described in detail later.
  • the Mn content should be from 0.25 to 1.0% as in the case of conventional flaky graphite cast iron.
  • the Mn content should be in the above range, because if the Mn content is 0.25% or more, the cast iron can have increased strength and hardness, but if the Mn content is more than 1.0%, the cast iron may be chilled so that it may be made hard and brittle.
  • the P content should be 0.04% or less as in the case of conventional flaky graphite cast iron.
  • the P content should be in the above range, because if the P content is more than 0.04%, P may react with iron to form steadite, a hard compound, which makes the cast iron brittle.
  • the S content should be 0.03% or less as in the case of conventional flaky graphite iron. This is because if the S content is more than 0.03%, the molten metal may have poor fluidity, and the cast iron may be chilled so that it may be made hard and brittle.
  • the carbon equivalent represented by formula (1) above is from 3.30 to 3.95%. As the carbon equivalent increases, the vibration damping capacity increases, but Young's modulus decreases. Both of them cannot be simultaneously improved by increasing or decreasing the carbon equivalent, but the carbon equivalent should be set at an adequate value, because it has a significant effect on the vibration damping capacity and Young's modulus.
  • the eutectic composition at which the eutectic reaction between austenite and graphite occurs, changes from that of conventional flaky graphite cast iron. In conventional flaky graphite cast iron, the eutectic reaction occurs when the carbon equivalent represented by formula 1 is 4.3%. However, when Al is added, the eutectic reaction may occur at a carbon equivalent smaller than this value. When the carbon equivalent is larger, than the value of the eutectic composition, the cast iron can be hypereutectic to have a significantly reduced Young's modulus, which is not preferred.
  • the vibration damping capacity may be significantly improved, but Young's modulus may be significantly reduced. This may be because at such a carbon equivalent, the cast iron exceeds the eutectic composition to have a hypereutectic composition.
  • the carbon equivalent is small, the amount of the formation of graphite will be small so that Young's modulus may be improved. In this case, however, the vibration damping capacity may be reduced, and therefore, the carbon equivalent should be 3.3% or more.
  • the carbon equivalent is defined to be from 3.30 to 3.90.
  • the temperature of the heat treatment conducted after the casting is from 280 to 630° C.
  • the improvement of the performance by heating and cooling significantly varies with the heating temperature.
  • the effect of the heat treatment is shown in FIG. 1 . While FIG. 1 shows cases where Al and Sn were added in the production of the materials according to the present invention, almost the same tendency was observed when only Al was added.
  • the heat treatment temperature is lower than 280° C. or is more than 630° C., the effect of the heat treatment is small.
  • the heat treatment be conducted at a temperature in the range where the ratio of improvement of the damping capacity is 5% or more, i.e., in the range of 280 to 630° C., before cooling.
  • the temperature range where the effect is improved by 20% or more is from 360 to 580° C. A high effect can be produced in these temperature ranges, and the highest effect can be obtained by heating to 500° C. followed by cooling.
  • the cooling method may be any of furnace cooling and air cooling. The reason why the damping capacity is improved by the heat treatment is not clear.
  • the heat treatment process may vary with the process performed after the casting of the product according to the present invention.
  • the heat treatment should be performed after the casting.
  • the heat treatment is most preferably performed after the machining.
  • the heat treatment may be performed before the machining.
  • the composition of cast iron was controlled using a high-frequency melting furnace.
  • a cast iron ingot produced with FC 300, a carburizing agent, ferromanganese, and silicon carbide were added to a graphite crucible and melted. Thereafter, the carbon content and the silicon content were adjusted with ferrosilicon and a carburizing agent, and thus about 20 kg of molten metal were obtained.
  • the Al content and the tin content of the obtained cast product were adjusted by the addition of ferroaluminum and pure tin, respectively.
  • the melting temperature was set at about 1,450° C. Before tapping, a Ca—Si—Ba—based inoculant was added to the melt, and then the melt was cast into a furan self-hardening mold of ⁇ 30 ⁇ 300 mm.
  • the resulting cast product was worked into a size of 4 ⁇ 20 ⁇ 200 mm and then measured for logarithmic decrement as an index of vibration damping capacity and for dynamic Young's modulus. In this case, a comparison was made between heat-treated and non-heat-treated products. In Examples 1 to 8, the Al-containing cast iron was heat-treated, while in Comparative Examples 1 to 8, the Al-containing cast iron was not heat-treated.
  • the test method was according to JIS G 0602. Specifically, the test piece was suspended from two points and given 1 ⁇ 10 ⁇ 4 of strain amplitude by an electromagnetic vibrator. The vibration was then stopped for free damping, and the logarithmic decrement and the dynamic Young's modulus were determined. The characteristics of the resulting cast products are shown in Table 1 below.
  • the logarithmic decrement is a value measured when the strain amplitude of the vibration was 1 ⁇ 10 ⁇ 4 .
  • Table 1 shows nothing about P or S, P ⁇ 0.025, and S ⁇ 0.020. Different Examples with the same composition mean that they are from the same melt but different cast samples.
  • FIG. 2 shows that concerning the Young's modulus-logarithmic decrement characteristics, the performance of the heat-treated products according to the present invention is improved by about 40% as compared with Comparative Examples 1 to 8 (non-heat-treated products).
  • This value indicates that the performance of the cast iron according to the present invention is about 2.5 to 3.0 times higher than that of FC 250 or FC 300, cast iron currently used (which shows a logarithmic decrement of about 100 ⁇ 10 ⁇ 4 , when Young's modulus is 120 PGa).
  • the melt was cast into a furan self-hardening mold of ⁇ 30 ⁇ 300 mm using the same process as in Examples 1 to 8 and Comparative Examples 1 to 8.
  • the resulting cast product was worked into a size of 4 ⁇ 20 ⁇ 200 mm and then measured for logarithmic decrement as an index of vibration damping capacity and for dynamic Young's modulus. In this case, a comparison was made between heat-treated and non-heat-treated products.
  • the Al and Sn-containing cast iron was heat-treated, while in Comparative Examples 9 to 16, the Al and Sn-containing cast iron was not heat-treated.
  • the test method was according to JIS G 0602. Specifically, the test piece was suspended from two points and given 1 ⁇ 10 ⁇ 4 of strain amplitude by an electromagnetic vibrator. The vibration was then stopped for free damping, and the logarithmic decrement and the dynamic Young's modulus were determined.
  • the characteristics of the resulting cast products are shown in Table 2 below.
  • the logarithmic decrement is a value measured when the strain amplitude of the vibration was 1 ⁇ 10 ⁇ 4 .
  • Table 2 shows nothing about P or S, P ⁇ 0.025, and S ⁇ 0.020. Different examples with the same composition mean that they are from the same melt but different cast samples.
  • FIG. 3 shows that concerning the Young's modulus-logarithmic decrement characteristics, the performance of the heat-treated products according to the present invention is improved by about 30% as compared with Comparative Examples 9 to 16 (non-heat-treated products).
  • This value indicates that the performance of the cast iron according to the present invention is about 3.5 times higher than that of FC250 or FC300, cast iron currently used (which shows a logarithmic decrement of about 100 ⁇ 10 ⁇ 4 , when Young's modulus is 120 PGa).
  • the present invention are not limited by the very embodiments described above, and in the practice of the present invention, the composition of Al, Sn, C, Si, Mn, P, S, or the like may be appropriately changed without departing from the gist of the present invention. Further, different compositions described in the embodiments may be appropriately used in combination.

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JP2008142932A JP5618466B2 (ja) 2008-05-30 2008-05-30 高剛性高減衰能鋳鉄
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US20200182318A1 (en) * 2018-12-11 2020-06-11 Hyundai Motor Company Brake disk including decarburized layer and nitride compound layer, and method of manufacturing the same

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DE112014002442B4 (de) 2013-05-14 2019-07-11 Toshiba Kikai Kabushiki Kaisha Gusseisen hoher Stärke und hoher Dämpfungsfähigkeit
KR102240112B1 (ko) * 2014-02-21 2021-04-14 두산공작기계 주식회사 편상 흑연 주철 및 이의 제조 방법

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WO2013117190A3 (de) * 2012-02-07 2015-04-02 Ford-Werke Gmbh GUßEISENWERKSTOFF UND FAHRZEUGTEIL AUS DEM GUßEISENWERKSTOFF
US9783875B2 (en) 2012-02-07 2017-10-10 Ford-Werke Gmbh Cast iron material and motor vehicle part made of the cast iron material
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US20200182318A1 (en) * 2018-12-11 2020-06-11 Hyundai Motor Company Brake disk including decarburized layer and nitride compound layer, and method of manufacturing the same
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US11137041B2 (en) * 2018-12-11 2021-10-05 Hyundai Motor Company Brake disk including decarburized layer and nitride compound layer, and method of manufacturing the same
KR102657327B1 (ko) 2018-12-11 2024-04-12 현대자동차주식회사 탈탄층 및 질화층을 포함하는 브레이크 디스크 및 이의 제조방법

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DE112009001294B4 (de) 2013-10-31
US20140000832A1 (en) 2014-01-02
DE112009001294T5 (de) 2011-04-14
KR20100139117A (ko) 2010-12-31
KR20130019002A (ko) 2013-02-25
JP2009287103A (ja) 2009-12-10
KR101268160B1 (ko) 2013-05-27
WO2009145039A1 (ja) 2009-12-03
JP5618466B2 (ja) 2014-11-05
KR101423892B1 (ko) 2014-07-28

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