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MURAKAMI Toshiyuki*2
Abstract:
Free cutting steel consists of two types, one for
machine structural use and the other based on low carbon steel for hard cutting, such as SAE 12L14. Conventionally, Pb has been added to free cutting steels to
improve their machinability, but Pb in steel is thought to
have a harmful effect on the human body. Therefore, as
alternatives to Pb addition in free cutting steels, JFE
Steel and NKK BARS & SHAPES studied graphite precipitation in the steel and control of the sulfide morphology by the chemical composition and developed new
Pb-free free cutting steels based on these respective concepts. In the graphite-type free cutting steel for machine
structural use, JFE Steel realized machinability equal to
that of the Pb-added steel by controlling the state of
existence of C in the steel, and achieved an excellent
balance of cold workability and high fatigue strength
after quenching and tempering. As a substitute for the
low carbon Pb-added free cutting steel (SAE 12L14),
NKK BARS & SHAPES developed a steel with improved
machinability by crystallizing large sulfide inclusions,
which is realized by increasing S addition while also
adding Cr on the basis of the estimation from the calculated phase diagrams.
1. Introduction
Free cutting steels with Pb addition are widely used
as materials for automobile and industrial machinery
parts. However, in recent years, the use of Pb has been
considered a problem from the viewpoint of environ
mental protection.
Free cutting steels can be broadly classified into two
types, (1) a free cutting steel for machine structural use,
in which cold forgeability and high strength, are required
simultaneously with machinability, and (2) so-called low
carbon free cutting steels, in which machinability with a
low carbon composition is the primary requirement, as
represented by SAE 12L14.
As alternatives to Pb addition for improving machinability, JFE Steel and NKK BARS & SHAPES developed free cutting steels by utilizing graphite precipitation in the steel and controlling the sulfide morphology
by the chemical composition of the steel, corresponding
to these respective applications. This paper introduces
these steels.
2. Graphite-Precipitation-type
Pb-free Free Cutting Steel
for Machine Structural Use
2.1 Background of Development
The steel for machine structural use is required to
possess machinability, fatigue strength after quenching and tempering, cold forgeability, and so on. Because
inclusions, including Pb added to improve machinability,
impair fatigue strength and cold forgeability, it had been
considered difficult to satisfy these property requirements simultaneously. Therefore, the development of a
steel which could satisfy the requirements of machinability, fatigue strength after quenching and tempering,
74
*2
Senior Researcher,
Research & Development Dept.,
Sendai Works,
NKK BARS & SHAPES
Bar and Wire Steels For Gears and Valves of AutomobilesEco-friendly Free Cutting Steel without Lead Addition
As rolled
Hot rolling
Fe3C (Cementite)
After graphitizing
Graphitizing
Cold forging
Machining
Quenching
and
tempering
Final product
50 m
Solute C
(Dissolved into martensite)
10
C (Graphite)
Final product
8
Si addition
6
Fe-0.45C-Cr
4
2
0
Fe-0.45C-0.6Si-Cr
0
0.5
Cr content (mass%)
75
Bar and Wire Steels For Gears and Valves of AutomobilesEco-friendly Free Cutting Steel without Lead Addition
Mn
Cr
0.45
0.6
0.3
trace
0.002 0
0.004 0
JIS S45C
0.45
0.25
0.8
0.15
0.005 0
2.2.3 Increase in
number of graphite nucleation sites
utilizing BN
Fine dispersion of graphite particles in steel is
effective both for preventing deterioration of fatigue
strength and for shortening the graphitization time. To
achieve fine dispersion of graphite particles, it is necessary to increase the number of nucleation sites. In this
development, acceleration of graphite nucleation by precipitates in the steel was studied. Although nucleation
of graphite particles was accelerated by the existence
of various types of precipitate in the steel, BN was an
extremely effective nucleation site.3,4)
In addition to the crystallographic structure of the
precipitates, graphite and BN also bear an extremely
close resemblance in terms of their precipitation modes.
Therefore, epitaxial formation and growth of graphite on
the surface of BN are easy, and BN in steel can be used
very effectively as a graphite nucleation site.
Based on these results, a chemical composition with
the following features was selected for the developed
steel. First, in order to destabilize cementite, the contents
of Mn and Cr were reduced and that of Si was increased
in comparison with the conventional steel for machine
structural use. To increase the amount of BN which can
serve as a nucleation site for graphite, the contents of B
and N were optimized. An example of the main chemical
composition of the developed steel is shown in Table 1
in comparison with the JIS S45C as a steel for machine
structural use.
Because graphitization of all cementites in steel
is not necessarily required, the necessary properties
are obtained by a combination of the reduction in the
amount of cementite, accompanying partial graphitization of cementite, and shape control of the remaining
cementite. Utilizing a three-phase structure consisting of
ferrite, graphite, and spheroidized cementite, refinement
of graphite particles simultaneously with a further simplification of softening annealing is possible.
Si
Cold
forgeability
C
Developed
steel
65
Good
60
55
50
Developed steel
Leaded
Unleaded
45 2
10
Bad
Conventional steel
103
Tool life in turning test(s)
Bad
Machinability
104
Good
Cutting condition
Speed : 200 m/min
Depth : 2 mm Feed : 0.25 mm/rev
700
Fatigue strength after quenching
and tempering
(MPa)
Developed steel
Un-leaded
600
Conventional
steel
500
Leaded
400
300 2
10
103
Tool life in turning test (s)
Bar and Wire Steels For Gears and Valves of AutomobilesEco-friendly Free Cutting Steel without Lead Addition
strength exceeding 500 MPa after quenching and tempering. In comparison with the size of the inclusions in
the conventional free cutting steel, which is on the order
of several 10s of micro meter, the graphite particles are
fine, at several micro meter, due to the increase in the
number of nucleation sites using BN. Furthermore, the
graphite in the steel dissolves into the steel matrix due
to heating during quenching. It should be noted that,
although unsolved BN also exists in the developed steel,
its size is about 1 m. Thus, because the graphite and
BN used in the developed steel are both fine, unlike the
conventional inclusions, they are thought to have no negative effect on fatigue strength.
The developed steel can be used in a wide range of
applications in steel for machine structural use, centering on parts where the conventional Pb-added steel had
been used and cold forging applications where machinability is a problem and high strength had been difficult
to realize.
Bar and Wire Steels For Gears and Valves of AutomobilesEco-friendly Free Cutting Steel without Lead Addition
BCCFCC
Liq.BCCFCC(Cr, Mn)S
BCCFCC(Cr, Mn)S Liq.FCC(Cr, Mn)S
FCCLiq.2(Cr, Mn)S
1 300
FCC
FCC(Cr, Mn)S
1 200
1 500
BCC
Liq.
Liq.BCCFCC
BCCFCCMnS
BCCFCC
1 400
Liq.BCCFCCMnS
FCC
1 300
FCC MnS
1 200
Pb free (1%Cr-0.4%S)
1 100
0
0.1
0.2 0.3
S (mass%)
0.4
Liq.BCCMnS
SAE 12L14
0.5
1 100
0
0.1
0.5
Pb free
1.0
0.8
Solidus
temperature
SAE 12L14
0.6
0.4
0.2
Mass of
Rolling
unsolved
sulfide
heat
temperature
0
1 000 1 100 1 200 1 300 1 400 1 500 1 600
Temperature (C)
Fig. 6 Mass of unsolved sulfide of Pb free steel in comparison with SAE12L14 steel
result for the conventional steel, SAE 12L14. The crystallization temperature range for sulfide inclusions with
SAE 12L14 is 19C, but in contrast, the crystallization
temperature range for the developed steel is expanded by
more than four times, to 93C.
In the study process, the amount of precipitated sulfides in the developed steel was also calculated. The
amount of sulfide precipitates is obtained, as shown in
Fig. 6. It can be understood that the amount of sulfides
unsolved during reheating for rolling is far larger in the
developed steel than in SAE 12L14. It was predicted
that this fact would suppress austenite grain growth during reheating and, by functioning as nuclei for the ferrite
transformation, would contribute to refinement of the
microstructure of the rolled material. The refinement of
microstructure improves machinability in the same manner as increasing the size of sulfide inclusions. 10) This is
presumably the first time that such new knowledge could
be predicted by calculation.
3.2.2 Confirmation experiments
with experimental melting furnace steel
Among the compositions which were studied by
calculation, test melting and machinability test were
actually conducted with the systems which were considered to be candidates for a new Pb-free free cutting
steel, and the confirmation tests for the final alloy composition were performed.
The samples were melted in a 150 kg vacuum melt78
0.4%S 0.3%S
Crack formation on forging
(Poor hot ductility)
Poor machinability
(Small sulfide inclusions)
Good machinability
(Large sulfide inclusions)
1.25
1.00
Mn (mass%)
1 400
Liq.
BCC
Liq.BCCFCC
Liq.BCC(Cr, Mn)S
Liq.BCC
Temperature (C)
Temperature (C)
1 500
0.75
0.50
Pb free
0.25
0
0.5
1.0
1.5
Cr (mass%)
2.0
2.5
Pb free
SAE 12L14
40 m
Bar and Wire Steels For Gears and Valves of AutomobilesEco-friendly Free Cutting Steel without Lead Addition
oped steel.
As described above, the 1%Cr-0.4%S steel was
adopted as the Pb-free free cutting steel as a result of confirmation tests with experimental melting furnace steel
conducted based on predictions from the phase diagram
calculations.
SEM
Cr
Mn
Si
Mn
Cr
Pb
Pb free
0.05
trace
0.58
0.076 0.385
1.00
trace
SAE 12L14
0.07
trace
1.05
0.070 0.340
0.08
0.24
Pb free
298
401
36
57
SAE 12L14
289
409
30
43
Pb free
SAE 12L14
tions:11)
(1) Turning machinability with carbide, coated carbide,
and cermet tools (tool life and machined surface
roughness)
(2) Turning machinability with high speed steel tool
(tool life and machined surface roughness)
(3) Drilling machinability with high speed steel tool
(tool life)
(4) Shape of chip
The relationship between tool wear (flank wear) and
the cutting time in turning and the relationship between
machined surface roughness (maximum roughness) and
the cutting velocity, in both cases with a carbide tool
(JIS P20) are shown in Fig. 8 and Fig. 9, respectively. In
comparison with SAE 12L14, the progress of tool wear
is gradual and the tool life is satisfactory for the developed steel. Similarly, the machined surface roughness
of the developed steel is equal to or smaller than that of
SAE 12L14 at all cutting velocities, and is therefore satisfactory.
Figure 10 shows the relationship between drill wear
and the number of holes drilled with a 10 mm diameter high speed steel drill (JIS SKH51). As for the turning machinability, the progress of drill wear was rapid
for SAE 12L14. Abnormal sound was heard when drilling exceeded approximately 1 450 holes, and it became
impossible to continue drilling. In contrast, no such phenomena were noted with the developed steel, and it was
possible to drill more than 1 500 holes, showing good
drilling machinability.
3.3.4 Other properties
10 m
Figure 11 shows an example of carburization characteristics. Both carburization property and case depth
were similar to those of SAE 12L14.
79
Bar and Wire Steels For Gears and Valves of AutomobilesEco-friendly Free Cutting Steel without Lead Addition
0.4
900
Gas carburizing : 930C 2 h / Oil Quenching
Tempering : 180C 1 h / Water Quenching
MHV300 gf
SAE 12L14
0.3
Flank wear (mm)
Pb free
0.2
Tool : P20
V 250 m/min
f 0.2 mm/rev
d 2.0 mm
Dry
0.1
10
20
30
Cutting time (min)
40
600
300
2
3
Depth from surface (mm)
25
SAE 12L14
20
f 0.2 mm/rev
Pb free
15
Tool : P20
d 2.0 mm
Dry
10
f 0.05 mm/rev
50
100
150
200
250
Cutting velocity (m/min)
300
0.6
Tool : SKH51 (10 mm)
Hole depth : 30 mm
V 63 m/min
f 0.35 mm/rev
Wet
0.4
References
SAE 12L14
0.2
Pb free
0
500
1 000
1 500
Number of holes
4. Conclusion
This paper has introduced two new Pb-free free cutting steels, a free cutting steel for machine structural use
and a substitute for SAE 12L14, which were developed
in response to customers needs from the viewpoint of
global environmental problems.
The graphite-precipitation type Pb-free free cutting
steel for machine structural use contains no substances
which are harmful to the environment and possesses
excellent machinability and cold forgeability, amply sat80