Bi-metal machining presents challenges with regard to the performance requirements of the metalworking fluid used. Common bi-metal operations include face milling of aluminum engine blocks containing a ferrous metal cylinder sleeve and reaming of engine crankshaft bores comprised of aluminum paired with a ferrous metal bearing cap. While the mechanical, thermal and wear properties of the two dissimilar metals serve to fulfill specific design features, the simultaneous machining of the two dissimilar metals often give rise to problems with machined surface finish, elevated cutting forces, machined part dimensions, as well as accelerated tool wear. This session will discuss the machining properties of bi-metal parts, methods useful for studying machinability and fluid performance, as well as insight into the compositional and property features of metalworking fluids best suited for use in such operations. Primary topics: a. Machining challenges associated with machining dissimilar metals b. Machining test conditions useful for studying metalworking fluid performance in aluminum engine block deck face milling c. Machining conditions useful for studying metal working fluid performance in bi-metal crank bore reaming d. Fluid requirements necessary for effective bi-metal machining performance

1. © 2017 Quaker Chemical Corporation. All rights reserved.
Senior Research Scientist
Metalworking
Your Presenter :
Dr. Robert Evans
Over 39 years of
experience in the
research and development
of industrial metalworking
lubricants and rust
preventives
evansb@quakerchem.com
Lubrication & Metalworking Fluid
Performance in the Machining of Ferrous
Metal-Cast Aluminum Bi-Metal Components
Welcome

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A Global Partner
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Major supplier of metalworking fluids to the automotive, heavy
equipment and related industries
Technical centers with fully instrumented machining
centers at all global regions
Significant research effort committed to supporting the emerging
trends in automotive engine manufacturing
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A Global Partner

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Increased Fuel
Efficiency
Reduced
Emissions
Lighter weight to engine
and associated
components
Stronger materials for
engine and associated
components
New highly engineered materials and material
combinations
Machining Challenges
Trends

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» Case hardened hydroformed cam shafts
» Higher strength, wear resistant valve seats
» Increased use of titanium & nickel based alloys
» Use of high strength cast irons
» Use of bi-metallic components
Examples

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What is Bi-Metal Machining
Simultaneous machining of two dissimilar
materials whereby one material serves to
provide light weighting, while the second
fulfills a role requiring high strength, and
thermal resistance

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Eg: Aluminum engine blocks – lighter weight
Cast iron cylinder sleeves
Cast iron or powdered ferrous
metal bearing caps
Bi-Metal Machining in Engine Production
Crankshaft Bore Reaming Deck Facing of Engine Block
®2017 Quaker Chemical Corporation. All rights reserved.

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» Differences in mechanical and thermal properties
between the two materials
» Compromise on the machining conditions and
tooling used
Why are bi-metal parts difficult
to machine?

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» Ductile Cast Iron
» Ferrous Powdered Metal
Bi-Metal Crankshaft Bore
» Aluminum-Silicon Cast Alloy
Differences in Mechanical &
Thermal Properties

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Differences in Mechanical &
Thermal Properties
µm/m·K (20-100ºC)

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Large differences in friction properties between
the two metals
Impact on quality of reamed bore surface
finish and bore cylindricity
Elevated machining vibrations & cutting forces
Differences in Mechanical &
Thermal Properties

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Polycrystalline Diamond
» Best for aluminum
» Incompatible with ferrous metals
Carbides
» Accelerated wear from silicon in aluminum
» Good for ferrous
» Aluminum Higher is better
» Iron Lower is better
Tooling
Compromise on Tooling &
Machining Conditions
Cutting Speeds

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Compromise on Tooling &
Machining Conditions

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Machining Test Criterion
» Effectively simulates the actual machining process
» Replicates the drop in machinability with bi-metal bores
Studying Crank Bore Reaming

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FC 0208 Powdered Metal
Aluminum 356-T6
Simulation of Crank Bore Reaming
in Laboratory Machining Tests
Aluminum – Aluminum bore for
baseline performance
Pearlite
Ferrite
Porosity

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15.87 mm dia. 6-fluted carbide
reamer
@ v = 30 m/min
f = .152 mm/rev
Bi-Metal Reaming Operation

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Bi-Metal Reaming Operation

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Machinability assessed via
1. Reamed hole cylindricity
2. Reamed surface roughness
Bi-Metal Reaming Operation

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Poor cylindricity gives rise to unstable hydrodynamic lubrication
conditions and potential points of metal-metal contact
Importance of Cylindricity & Finish
Operates in a hydrodynamic regime of lubrication

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Importance of Cylindricity & Finish
High roughness with the bore surface will negatively affect heat transfer
from the journal bearings to the surrounding metals

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Using a CMM
Cylindricity Results

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Aluminum Surface Finish Results
Aluminum-Aluminum
Part
Aluminum-Powdered
Metal Part
Using a standard semi-synthetic Aluminum machining fluid
Reamed aluminum surface –
from Aluminum-Aluminum part
Reamed aluminum surface –
from Aluminum-PM part

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» High level of lubrication to maintain constant
friction and stable cutting forces during
continuously changing and alternating cutting
conditions
QUAKERCOOL® 7450
Semi-synthetic metalworking fluid designed
for aluminum & bi-metal machining
» Provides high lubrication on ferrous metals
without compromise or detriment to the
aluminum machining performance of the fluid

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Cylindricity of Reamed Holes

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Reamed Aluminum Surface Finish

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» Leaves machines clean
» Good tramp oil rejection
» Consistent performance over a wide
range of water/emulsion hardness
QUAKERCOOL® 7450 Aluminum &
Bi-Metal Machining Fluid Experience
Globally utilized by many automotive OEMs and Tier 1 & 2
manufacturers for the machining of aluminum engine blocks,
cylinder heads, and associated components (valve seats and
guides, steering components, fuel injectors etc.)
» Long sump life and low consumption
» Provides Myco bacteria resistance &
bio stability against bacteria & fungi

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Bi-metal machining presents significant challenges
with regard to machinability and the quality of the
part produced
QUAKERCOOL® 7450 - Metalworking fluid designed
for effective performance on both aluminum and
ferrous metals - can offer significant benefit in bi-
metal machining operations
Conclusions: Bi-Metal Machining

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Bi-Metal Machining – Crank Bore Reaming
Taylor Grimm, Ingvar Jochumsson, Michael Hanlon, John O’Brien
Department of Industrial & Manufacturing Engineering and Department of
Materials Science & Engineering
The Pennsylvania State University
Acknowledgements

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30
Thank You
Dr. Robert Evans
Senior Research Scientist
Metalworking Research Laboratory
Quaker Chemical Corporation
evansb@quakerchem.com