Usinagem do alumínio da classe 6005 com uso de ferramenta cerâmica

The machining process is so much important in the economic world. Many machining parameters have been studied to maximize results, in terms of cost and lifetime. (decrease of cutting tool wear, improved surface finish, among others). The objective of this study is to evaluate the wear of a ceramic tool in the machining of the aluminum alloy 6005 A. The analysis of the wear of the cutting tools is very important due to its big impact on the final finishing of the piece as a whole. The evaluation took place in two stages, first it was done a detailed study of the literature of the whole machining process, where the study of the formation and swarf classification were among the most important steps in this phase. The second step consisted in the machining of the piece of aluminum 6005 A with a ceramic cutting tool constituded of aluminum oxide and magnesium oxide with silicon carbide impregnation. The swarf generated in this process was then photographed with a Zeiss optical microscope and analyzed for its size and shape. Through this comparison it was concluded that the swarf are generated shear swarfs, shaped like a tangled, fragmented and arcs connected, thus classifying the material as medium difficulty machining. Through the image analysis tool it was concluded that the parameter of lower wear was the: Vc = 500m / min, f = 0.10mm / rev and ap = 0.5mm

Estudo da utilização de ferramentas a base de nitreto de silício (Si3N4) e alumina (Al2O3) na usinagem do ferro fundido vermicular

Machining is one of the most commonly manufacturing processes used in the modern world, consuming millions of dollars annually. Because of this, it is crucial for the automotive industry to reduce costs on their heat-resistant alloy machining processes, such as compacted graphite iron (CGI), which has shown an increasing trend of its application in diesel engine blocks, brakes disks, among other applications, due to its superior mechanical properties to gray cast iron. Despite this advantage, its use is still limited due to its difficulty of machining, moreover, cutting tools are displayed as the main factor in increasing the machining cost. Seeking an alternative to a better machinability of CGI, this paper aims to study two types of ceramic tools developed in Brazil, and benchmark their performance by dry turning. For this, were used CGI class 450 and two tools: ceramic of silicon nitride (Si3N4) and alumina-based (Al2O3), with a cutting speed (Vc) of 300, 400 and 500 m / min; feed (f) of 0.2 mm / rev and depth of cut (ap) of 0.5 mm, using three replicates and starting with new cutting edges. The results showed that the Al2O3 tool had the best performance in Vc of 500 m / min, while the Si3N4 tool had the best results in Vc of 300 m / min. This can be explained by the tool of Si3N4 based include soft intergranular phase, called amorphous, while alumina has higher abrasion resistance due to its high refractoriness. The results make it clear that the tools have significant potential for machining of compacted graphite iron, being necessary a strict control of the cutting parameters used

Torneamento da liga de alumínio da classe 6005 utilizando ferramenta cerâmica

Machining processes are one of the most important manufacturing processes in the modern world. In these processes, there are many elements which will influence in the final result of the machined part. Among them, the tools are the principal factor of the rising cost, because its global influence on the process. In aeronautical industries, this can be more evidenced due the need to machining several alloys, between them, aluminum alloys. These alloys have to demonstrate a specific surface finishing to be used in aircraft's fuselage. This kind of industry is one of the segments which is still rising in Brazil, and they are looking viable alternatives in the manufacturing processes of materials, due the need to produce more and more parts and equipment, with costs increasingly reduced. The purpose of this project is the development of a ceramic with differentiated properties. The ceramics were developed using a pre-sintering at 1200 °C, with posterior sintering at 1600°C, and subjected to dry turning process on aluminum alloy 6005. The characterizations showed that ceramics presented with toughness on the center of 1700 MPa and on the surface of 1950 MPa, density 98,5 ±0,14. g/cm³. Ceramics were grinded and faceted, according to ISO standard 1832, and subjected to turning tests in a ROMI lathe brand, model GL240M, using cutting speeds of 500, 800 and 1000 m/min with different feed rates. The machining results showed low occurrence of flank wear to all cutting speeds, and better surface finishing average values of Ra = 0,4935 μm and Rt = 8,112 μm. In general, it could be seen that the tool presents important potential to machining 6005 alloy, and that the use of correct parameters can decrease and/or eliminate subsequent processes, providing important reductions in costs related to the machining processes