Improvement of machinability of vermicular cast iron in the manufacture of brake discs and drums used in high-speed trains

This study investigates the effect of laser texturing on carbide inserts in the milling of vermicular cast iron, commonly used in high-speed train brake disc manufacturing. The objective was to evaluate the performance of laser-textured tools compared to blast-textured ones, applying different coatings (TiAlN-Futura®, AlCrN-Alcrona® and AlCrN-Helica®). Life tests were conducted under various cutting conditions, including cutting speed, depth of cut, and feed per tooth, without the influence of cutting fluids. The results demonstrated that laser-textured tools removed significantly higher volumes of material than blast-textured tools. Cutting speed and depth of cut were the most influential parameters on tool life, with cutting speed showing statistical significance across all tools. The TiAlN-Futura® and AlCrN-Helica® coatings proved to be the most efficient under the tested conditions. The study concludes that laser texturing is a viable alternative to conventional blasting for enhancing tool performance in the milling of vermicular cast iron.