Surface amorphization in diamond turning of silicon crystal investigated by transmission electron microscopy

Silicon crystal exhibits a ductile regime during machining prior to the onset of fracture when appropriate cutting conditions are applied. The present study shows that the ductile regime is a result of a phase transformation which is indirectly evidenced by the amorphous phase detected in the machined surface. Transmission electron microscopy (TEM) planar view studies were successfully performed on monocrystalline silicon (1 0 0) single point diamond turned. TEM electron diffraction patterns show that the machined surface presents diffuse rings along with traces of crystalline material. This is attributed to crystalline silicon immersed in an amorphous matrix. Furthermore, only diffuse rings in the diffraction patterns of the ductile chip are detected, indicating that it is totally amorphous. © 2000 Elsevier Science B.V. All rights reserved.

Cutting performance of diamond coated Si3N4 tool during turning

Silicon nitride cutting tools have been used successfully for machining hard materials, like: cast irons, nickel based alloys, etc. However these cutting tools with diamond coating present little information on dry turning operations of gray cast iron. In the present work, Si3N4 square inserts was developed, characterized and subsequently coated with diamond for dry machining operations on gray cast iron. All experiments were conducted with replica. It was used a 1500, 3000, 4500 m cutting length, feed rate of 0.33 mm/rev and keeping the depth of cut constant and equal to 1 mm. The results show that wear in the tool tips of the Si3N4 inserts, in all cutting conditions, was caused by both mechanical and chemical processes. To understand the tool wear mechanisms, a morphological analysis of the inserts, after experiments, has been performed by SEM and optical microscopy. Diamond coated PVD inserts showed to be capable to reach large cutting lengths when machining gray cast iron. © (2010) Trans Tech Publications.

A study on the viability of minimum quantity lubrication with water in grinding of ceramics using a hybrid-bonded diamond wheel

With the currently strict environmental law in present days, researchers and industries are seeking to reduce the amount of cutting fluid used in machining. Minimum quantity lubrication is a potential alternative to reduce environmental impacts and overall process costs. This technique can substantially reduce cutting fluids in grinding, as well as provide better performance in relation to conventional cutting fluid application (abundant fluid flow). The present work aims to test the viability of minimum quantity lubrication (with and without water) in grinding of advanced ceramics, when compared to conventional method (abundant fluid flow). Measured output variables were grinding power, surface roughness, roundness errors and wheel wear, as well as scanning electron micrographs. The results show that minimum quantity lubrication with water (1:1) was superior to conventional lubrication-cooling in terms of surface quality, also reducing wheel wear, when compared to the other methods tested.

Avaliação do desempenho de corte de diferentes grãos adiamantados

Por meio de um trabalho multidisciplinar entre Engenheiros e Dentistas, foram estudados oito diferentes tipos de grãos abrasivos de diamantes para a fabricação de pontas adiamantadas e/ou rebolos de pequeno diâmetro. Verificou-se qual o grão mais adequado para ser empregado nas pontas, as quais são utilizadas em equipamentos que possuem um pequeno torque disponível. Uma metodologia de experimentação para avaliação da capacidade de corte destas ferramentas foi desenvolvida, utilizando-se o vidro como material a ser desgastado. Como resultados, observou-se que a estrutura e a friabilidade do grão de diamante afetam diretamente a capacidade de corte das pontas adiamantadas. Desta forma, o melhor tipo de diamante foi aquele que apresentou, ao mesmo tempo, as melhores condições de remoção de material e o menor preço.

GREEN MACHINING ORIENTED TO DIMINISH DENSITY GRADIENT FOR MINIMIZATION of DISTORTION IN ADVANCED CERAMICS

After sintering advanced ceramics, there are invariably distortions, caused in large part by the heterogeneous distribution of density gradients along the compacted piece. To correct distortions, machining is generally used to manufacture pieces within dimensional and geometric tolerances. Hence, narrow material removal limit conditions are applied, which minimize the generation of damage. Another alternative is machining the compacted piece before sintering, called the green ceramic stage, which allows machining without damage to mechanical strength. Since the greatest concentration of density gradients is located in the outer-most layers of the compacted piece, this study investigated the removal of different allowance values by means of green machining. The output variables are distortion after sintering, tool wear, cutting force, and the surface roughness of the green ceramics and the sintered ones. The following results have been noted: less distortion is verified in the sintered piece after 1mm allowance removal; and the higher the tool wear the worse the surface roughness of both green and sintered pieces.

A sustainable alternative for cooling the machining processes using a refrigerant fluid in recirculation inside the toolholder

This article presents a cooling system for cutting tool in turning based in a toolholder with cooling fluid flowing inside its body being that this fluid must necessarily be able to phase change due to heat generated from machining processes. In this way, the fluid evaporates just under the cutting tool allowing a heat transfer more efficient than if were used a fluid without phase change once the latent heat of evaporation is beneficial for removal heat. Following, the cooling fluid evaporated passes through a condenser located out of the toolholder where it is condensated and returns to the toolholder again and a new cycle is started. In this study, the R-123, a hydrochlorofluorocarbon (HCFC) fluid, was selected for the turning of a Cr-Ni-Nb-Mn-N austenitic steel of hard machinability. The machining tests were carried out under three different machining conditions: dry machining, external cutting fluid (conventional method), and with the toolholder proposed. As result, the developed system allows a surface roughness up to 10% better than dry machining and a tool life close to the conventional method, but 32% superior to dry machining; moreover, there are environmental and economics advantages once the cooling fluid is maintained in a loop circuit.

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.

Surface finishing of flat pieces when submitted to lapping kinematics on abrasive disc dressed under several overlap factors

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

Micromorphologic assessment of CVD (chemical vapor deposition) and conventional diamond tips and their cutting effectiveness

The aim of this study was to compare the micromorphology of CVD diamond tips coupled to ultrasound with conventional high speed diamond tips after cavity preparations, and to measure the width and depth of the cavities obtained. Two hundred bovine teeth were divided into 20 subgroups. Each of the diamond tips (10 CVD and 10 conventional) were used to prepare 10 standardized cavities, using an apparatus that controlled the time (t: 27 s), speed (5.3 mm/s) and load (0.012 KGF) of the tip against the teeth during preparation. The unused and the used (after one, five and 10 preparations) tips were analyzed by scanning electronic microscopy. The images were randomly assessed by 3 examiners with regard to the presence or absence of micromorphologic alterations. Cavity measurements were made after visualization under a stereoscopic microscope. Cavity widths and depths were analyzed by the ANOVA Factorial test (p < 0.05). The CVD diamond tips presented less wear than the conventional tips after all the cavity preparations performed, but produced shallower cavities that were equivalent in width to those made by conventional tips after the fifth preparation. CVD diamond tips may be suggested as an alternative to conventional diamond tips due to their conservative preparation and greater longevity.

Evaluation of the Smear Layer and Hybrid Layer in Noncarious and Carious Dentin Prepared by Air Abrasion System and Diamond Tips

Purpose: To analyze the smear layer and the hybrid layer in noncarious and carious dentin prepared by different cutting instruments and restored with composite resin. Study design: Cavities were randomly prepared in 160 specimens (noncarious and artificial carious dentin) by high-speed diamond tips (KG Sorensen 1013), air abrasion system (Prepstart, Danville Engineering), ultrasonic tip (CVDentus 8.3231-1), and ultrasonic tip associated with ultrasonic cavitation by water for 10 s. Half of the cavities in each group were conditioned with 37% phosphoric acid for 15 s. The amount of smear layer and dentinal tubules present were analyzed using scanning electron microscopy and graded from 0 to 3. Cavities were prepared in another 20 noncarious specimens and 20 carious specimens and restored with adhesive composite resin system. The restorations were hemisected longitudinally and analyzed using scanning electron microscopy to evaluate the hybrid layer and resinous prolongation characteristics, using scores ranging from 1 to 6. Results: The data were statistically analyzed using Kruskal-Wallis and Dunn tests at 5% of significance level. There was evidence that the most efficient smear layer removal was the acid etching in the noncarious dentin and the water ultrasonic cavitation in the carious dentin. The hybrid layer formed on the noncarious and carious dentin prepared by the ultrasonic tip was more regular than in the specimens prepared by high-speed diamond tip, with many resinous prolongations. Conclusion: The ultrasonic tip seems to be a promising tool for carious dentin cavity preparation. Microsc. Res. Tech. 73:597-605, 2010. (C) 2009 Wiley-Liss, Inc.

Electroanalytical determination of carbendazim and fenamiphos in natural waters using a diamond electrode

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

Microshear Bond Strength of Self-etching Bonding Systems to Ultrasound Diamond Bur-prepared Dentin

Purpose: The aim of this study was to evaluate the influence of dentin abrasion on the microshear bond strength of two self-etching adhesive systems, using either an ultrasound diamond bur or a high-speed diamond bur.Materials and Methods: Twenty noncarious human third molars were sectioned mesiodistally into halves. The enamel was ground to expose a flat dentin surface on both sections. The dentinal surfaces were randomly assigned to two groups, depending on the method of smear layer preparation: ultrasound diamond bur (UB) or conventional diamond bur (CB). The prepared dentin surfaces received one of two self-etching systems: Clearfil SE Bond (CF) and One-Up Bond F (OB). A composite cylinder with a 0.95-mm diameter was bonded to each specimen and the microshear bond test was performed. The results were expressed in MPa and were subjected to two-way analysis of variance (ANOVA) and Tukey's test (alpha = 0.05).Results: There was no significant difference in dentin bond strength when comparing the conventional and ultrasonic abrasion methods. When the adhesive systems were compared, Clearfil SE Bond achieved higher bond strength means than did One-Up Bond F.Conclusion: The dentin surface preparation method did not influence the microshear bond strength and the Clearfil SE Bond adhesive system, independent of bur type used, Clearfil SE Bond showed higher bond strengths than did the One-Up Bond F adhesive system.

Electrochemical reduction of disperse orange 1 textile dye at a boron-doped diamond electrode

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