Investigation on Surface Finishing of Components Ground with Lapping Kinematics: Lapgrinding Process

Over the last three decades, researchers have responded to the demands of industry to manufacture mechanical components with geometrical tolerance, dimensional tolerance, and surface finishing in nanometer levels. The new lapgrinding process developed in Brazil utilizes lapping kinematics and a flat grinding wheel dressed with a single-point diamond dresser in agreement with overlap factor (U(d)) theory. In the present work, the influences of different U(d) values on dressing (U(d) = 1, 3 e 5) and grain size of the grinding wheel made of silicon carbide (SiC = 800, 600 e 300 mesh) are analyzed on surface finishing of stainless steel AISI 420 flat workpieces submitted to the lapgrinding process. The best results, obtained after 10 minutes of machining, were: average surface roughness (Ra) 1.92 nm; 1.19 mu m flatness deviation of 25.4 mm diameter workpieces and mirrored surface finishing. Given the surface quality achieved, the lapgrinding process can be included among the ultra-precision finishing processes and, depending on the application, the steps of lapping followed by polishing can be replaced by the proposed abrasive process.

Optical and mechanical design of an ophthalmic instrument: Slit lamp

This work has as objective to develop an interesting research line in the Optical Instrumentation area, that is to associate the Optical Design to the Ophthalmology area. The purpose of it is handling the optical design techniques to design a widely used ophthalmologic instrument called slit lamp. The optical and mechanical design of the slit lamp prototype was carefully projected in order to improve the best quality image, the comfort of the patient and the user, the simplicity of handling, the facility of production the availability of optical and mechanical components in the national market and the low cost of production. The main goal of this work was to realize a project using totally national technology, cheapening the cost and forming the optimum image required for the slit lamp optical system.

Influência da lubrirrefrigeração na qualidade superficial de metais retificados

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Analysis of surface integrity for minimum quantity lubricant - MQL in grinding

The quality of machined components is currently of high interest, for the market demands mechanical components of increasingly high performance, not only from the standpoint of functionality but also from that of safety. Components produced through operations involving the removal of material display surface irregularities resulting not only from the action of the tool itself, but also from other factors that contribute to their superficial texture. This texture can exert a decisive influence on the application and performance of the machined component. This article analyzes the behavior of the minimum quantity lubricant (MQL) technique and compares it with the conventional cooling method. To this end, an optimized fluid application method was devised using a specially designed nozzle, by the authors, through which a minimum amount of oil is sprayed in a compressed air flow, thus meeting environmental requirements. This paper, therefore, explores and discusses the concept of the MQL in the grinding process. The performance of the MQL technique in the grinding process was evaluated based on an analysis of the surface integrity (roughness, residual stress, microstructure and microhardness). The results presented here are expected to lead to technological and ecological gains in the grinding process using MQL. (c) 2006 Elsevier Ltd. All rights reserved.

Evaluation of WC-10Ni thermal spraying coating by HVOF on the fatigue and corrosion AISI 4340 steel

Shot peening is a surface process widely used to improve the fatigue strength of materials, through compressive residual stresses induced in their surface layers. Considering mechanical components for high responsible applications, wear and corrosion control is currently accomplished by the use of coated materials.In the case of chrome plating or hard anodizing, lower fatigue strength in comparison to uncoated parts are associated to high residual tensile stresses and microcracks density. Under constant or variable amplitude loading microcracks will propagate and cross the interface coating substrate without impediment.The aim of the present study is to analyze the influence of WC-10Ni coating applied by HVOF process on the axial fatigue strength of AISI 4340 steel. The shot peening effect on the fatigue performance of coated AISI 4340 steel was also evaluated. The fractured fatigue specimens were investigated using a scanning electron microscope in order to obtain information about the crack initiation points. (C) 2010 Published by Elsevier Ltd.

Evaluation of shot peening on the fatigue strength of anodized Ti-6Al-4V alloy

The increasingly design requirements for modern engineering applications resulted in the development of new materials with improved mechanical properties. Low density, combined with excellent weight/strength ratio as well as corrosion resistance, make the titanium attractive for application in landing gears. Fatigue control is a fundamental parameter to be considered in the development of mechanical components. The aim of this research is to analyze the fatigue behavior of anodized Ti-6Al-4V alloy and the influence of shot peening pre treatment on the experimental data. Axial fatigue tests (R = 0.1) were performed, and a significant reduction in the fatigue strength of anodized Ti-6Al-4V was observed. The shot peening superficial treatment, which objective is to create a compressive residual stress field in the surface layers, showed efficiency to increase the fatigue life of anodized material. Experimental data were represented by S-N curves. Scanning electron microscopy technique (SEM) was used to observe crack origin sites.

Effects of electroplated zinc-nickel alloy coatings on the fatigue strength of AISI 4340 high strength steel

It is well known that fatigue behaviour is an important parameter to be considered in mechanical components subjected to constant and variable amplitude loadings. In combination with corrosion phenomenon, fatigue effects were responsible for proximally 64% of fails that occur in metallic parts of aeronautical accidents in the last 30 years. Recovered substrates have been extensively used in the aerospace field. Cadmium electroplating has been widely applied to promote protective coatings in aeronautical components, resulting in excellent corrosion protection combined with a good performance in cyclic loading. Ecological considerations allied to the increasing demands for corrosion resistance, resulted in the search for possible alternatives. Zinc-nickel alloys received considerable interest recently, since these coatings showed some advantages such as a good resistance to white and red rust, high plating rates and acceptation in the market. In this study the effects of zinc-nickel coatings electroplated on AISI 4340 high strength steel were analysed on rotating bending and axial fatigue strength, corrosion and adhesion resistance. Compressive residual stress field was measured by a X-ray tensometry prior to fatigue tests. Optical microscopy images showed coating thicknesses, adhesion and the existence of an uniform coverage of nearly all substrates. The fractured fatigue specimens were investigated using a scanning electron microscope. Three different zinc-nickel coating thicknesses were tested and comparison with rotating bending fatigue data from specimens cadmium electroplated and heat treated at 190°C for 3, 8 and 24 hours to avoid the diffusion of hydrogen in the substrate, was performed. Experimental results showed effect of coatings on the AISI 4340 steel behaviour when submitted to fatigue testing and the existence of coating thickness influence on the fatigue strength.

Study of the phenomena of fatigue using the finite element method

About 99% of mechanical failures are consequence of the phenomena of fatigue, which consists on the progressive weakening of the resistant section of a mechanical component due to the growing of cracks caused by fluctuating loadings. A broad diversity of factors influences the fatigue life of a mechanical component, like the surface finishing, scale factors, among others, but none is as significantly as the presence of geometric severities. Stress concentrators are places where fatigue cracks have a greater probability to occur, and so on, the intuit of this work is to develop a consistent and trustfully methodology to determine the theoretical stress concentration factor of mechanical components. Copyright © 2007 SAE International.

Influência da velocidade de deslizamento no desgaste do par tribológico ferro fundido cinzento (MC 12 e MC 13) - ferro fundido cinzento centrifugado

Pós-graduação em Engenharia Mecânica - FEG

Projeto de uma roda para comporta vagão usando elementos finitos

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Fadiga em titânio aeronaútico revestido por PVD

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Atenuação dos níveis de ruídos em tratores agrícolas

Esta pesquisa analisou as diversas soluções para atenuar os níveis de ruído dos tratores e propor um projeto de redução do ruído na sua fonte. Para tal, se propôs projetar, executar e testar alterações em componentes mecânicos causadores de ruído nos tratores, fazendo com que esses níveis se enquadrem em valores considerados salubres. Todas alterações e ensaios foram executados num trator Massey Ferguson MF 290. Para a redução do ruído foram atacados as 3 fontes principais de ruído do trator : o sistema de exaustão de gases, a hélice do sistema de arrefecimento e o sistema de admissão de ar. Como conclusão final pode-se afirmar que é possível atenuar o ruído de tratores agrícolas até níveis salubres (que não causem perda de audição a seus operadores), atuando-se exclusivamente nas fontes de ruído (motor e seus acessórios).

Transportador de correia: componentes e cálculos básicos para seu dimensionamento

Increasingly, people searches for an efficient and economic way for transporting bulk materials. Transport through belts is now the most widely used mean for transporting bulk materials, used by companies from various sectors such as mining, quarrying, agribusiness, etc. There are many advantages of using a conveyor belt as compared to rail or by truck. Trucks needs a driver, have a high risk of accidents as well as a high cost for maintenance and as well as trains, after making the downloading of the material, return empty to the next load. The cost for the construction of a railway is very high, making it often impossible. The conveyor belt have a high cost of installation, but it works 24 hours a day, 365 days a year. The upper side of the belt is always loaded, the maintenance cost is average and the risk of accidents is low, causing it to be the ideal way to transport bulk materials. This monography aims to interest the reader about what is a conveyor belt, what are its main components and demonstrate the basic calculations for their sizing and selection of components. Throughout the work, scaled a belt conveyor for use in the mining sector, but the concepts demonstrated apply to the transport of any material

Contribution of electrical parameters on the dynamical behaviour of a nonlinear electromagnetic damper

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Avaliação de lubrificantes para aplicação em componentes mecânicos pelo método de compressão do anel

The current lubricants are getting better with advancing technology and more specific to each case of application. Its use is directly linked to the level of waste by friction generated between objects in direct contact and it is essential to promote greater durability of mechanical components. This study refers to behavioral assessment of some types of lubricants and rank among them which one presents the lowest friction between metal components. For this work, will be used the method of ring compression test (RCT), after performed tests and analyzed the results, will be possible to report which lubricant will bring the best reduction in friction. The need for this work was given initially by the observation that some mechanical projects developed at FEG does not conduct in-depth studies the lubricants used. Therefore this study aims to provide better support to these projects. In this work were used five different lubricants, three oils and two greases.