Chip Management in Milling and Drilling of Ductile Cast Iron

Sammanfattning: This paper presents a comprehensive cross-functional analysis of machining operations for ductile cast iron components in the automotive industry, focusing on the problem of chip carryover and its impact on downstream processes. The research aims to understand the role of machining and identify the source of the issue, by analyzing different machining sequences and the chips that affect the final product or subsequent production stages. To achieve this, the study initially focuses on a 5-axis machining production cell, evaluating the current choice of tooling systems and peripheral processes such as cooling, lubrication, and chip removal solutions. Based on empirical findings, the study presents newly developed solutions to address and minimize the problem of chip carryover in the current production context. These solutions include implementing new sequences of operations and optimizing peripheral processes to prevent chip buildup and reduce the need for manual intervention. The results of the study demonstrate the effectiveness of the proposed solutions in reducing production costs and improving product quality. Overall, this research highlights the importance of a broad and cross-functional approach for developing and implementing improved production strategies. By providing an alternative to a costly manufacturing issue, this study contributes to the ongoing efforts to improve the efficiency and sustainability of manufacturing processes in the automotive industry.