Studies on the cooling minimum quantity and conventional cooling at hardened steels in grinding process

The purpose of this work is to explain the concept of cutting fluids reasonable usage through the fluid minimum quantity in grinding processes. on that purpose, the development of a new nozzle and an own and adequate methodology should be required in order to obtain good results and compare them to the conventional methods. The analysis of the grinding wheel/cutting fluid performance was accomplished from the following input parameters: flow rate variation by nozzle diameter changes (three diameters values: 3mm, 4mm and 5mm), besides the conventional round nozzle already within the machine. Integral oil and a synthetic emulsion were used as cutting fluids and a conventional grinding wheel was employed. The workpieces were made of steel VC 131, tempered and quenched with 60HRc. Thus, as the flow rate and the nozzle diameter changes, keeping steady fluid jet velocity (equal to cutting velocity), attempted to find the best machining conditions, with the purpose to obtain a decrease on the cutting fluid volume, taking into consideration the analysis of the process output variables such as cutting strength, cutting specific energy, grinding wheel wear and surface roughness. It was verified that the 3mm diameter optimized nozzle and the integral oil, in general, was the best combination among all proposed.

Influence of the grinding wheel's dive speed on the damage of rectified hardened steels

The world tendency is the increase of the productivity and the production of pieces more and more sophisticated, with high degree of geometric and dimensional tolerances, with good surface finish and low cost. Rectification is responsible for the final finish in the machining process of a material. However, damages generated in this production phase affect all the resources used in the previous processes. Great part of the problems happennig in the rectification process is due to the enormous temperature generated in this activity because of the machining conditions. The dive speed, which is directly related to the productivity, is considered responsible for the damages that occur during rectification, limiting its values to those that do not cause such damages. In this work, through the variation of the dive speed in the process of cylindrical grinding of type ABNT D6 steel, rationalizing the application of two cutting fluids and using a CBN (cubic boron nitrate) abrasive wheel with vitrified blond, the influence of the dive speed on the surface damages of hardened steels was evaluated. The results allowed to say that the dive speed, associated to an efficient cooling and lubrication, didn't provoke thermal damages (including heated zones, cracks and tension stresses) to the material. Residual stresses and the roughness of rectified materials presented a correlation with the machining conditions. The work concluded that it is possible to increase the productivity without provoking damages in the rectified components.

Orientation dependence of stored energy of cold work in semi-processed electrical steels after temper rolling

Microhardness measurements were carried out in a low carbon lamination steel after 6% of temper rolling, in order to evaluate local variations of work hardening as a function of crystallographic orientation. EBSD (electron back scattered diffraction) was used to determine grain orientations with respect to individual rolling planes and rolling directions. Hardness was shown to increase with the local Taylor factor. TEM observations and a well-known dislocation hardening model were used to confirm the equivalence between hardness values and the stored energy of cold work. A definite correlation between stored energy and Taylor factors could therefore be established, being more consistent than previous data reported in the literature. The improvement was thought to be related to the rather small plastic deformation, during which Taylor factors could be considered to remain constant. (c) 2006 Elsevier B.V. All rights reserved.

Surface Integrity Analysis when Milling Ultrafine-grained Steels

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

Fatigue life studies in carbon dual-phase steels

An investigation has been conducted to examine the morphological influence on fatigue life of low carbon steel with dual phase microstructure. The results showed that dual-phase microstructure, composed by ferrite and martensite had superior symmetrical bending fatigue strength when compared with ferrite-pearlite steel. Through those tests, evidences of different mechanisms were verified (such as ferrite cyclic hardening, slip band formation and beginning of crack nucleation and propagation). Based on the fatigue tests results, various mechanisms stages were discussed associated with different microstructure morphology. Copyright (C) 1996 Published by Elsevier B.V. Limited.

Experimental and theoretical study of workpiece temperature when end milling hardened steels using (TiAl)N-coated and PcBN-tipped tools

The present work shows an experimental and theoretical study on heat flow when end milling, at high-speed, hardened steels applied to moulds and dies. AISI H13 and AISI D2 steels were machined with two types of ball nose end mills: coated with (TiAl)N and tipped with PcBN. The workpiece geometry was designed to simulate tool-workpiece interaction in real situations found in mould industries, in which complex surfaces and thin walls are commonly machined. The compressed and cold air cooling systems were compared to dry machining Results indicated a relatively small temperature variation, with higher range when machining AISI D2 with PcBN-tipped end mill. All cooling systems used demonstrated good capacity to remove heat from the machined surface, especially the cold air. Compressed air was the most indicated to keep workpiece at relatively stable temperature. A theoretical model was also proposed to estimate the energy transferred to the workpiece (Q) and the average convection coefficient ((h) over bar) for the cooling systems used. The model used a FEM simulation and a steepest decent method to find the best values for both variables. (c) 2007 Elsevier B.V. All rights reserved.

Spectrophotometric determination of manganese in steels by on-line electrochemical oxidation

The aim of this work is to propose a flow spectrophotometric procedure for manganese determination in steel based on electrochemical oxidation of Mn(II) to Mn(VII) at a Pt electrode surface by means of the catalytic effect of Ag(I). The on-line oxidation step was obtained by injecting sample and electrolyte solution directly into an electrolytic cell. After electrolysis, the injectate was homogenized by bubbling air. The permanganate ions produced were passed through the spectrophotometer where absorbance was monitored at 545 nm. Effects of direct current, silver concentration, timing, flow rates, concentration and composition of support electrolyte were investigated. Direct current and silver content manifested themselves as the most relevant parameters. For determination of manganese in the 5.00 - 150 mg L -1 range (r=0,9998) and 60 s electrolysis time, the sample throughput was 20 h -1. Accuracy was assessed by analyzing ten steel standard reference materials. Results are precise (R.S.D. <3%) and in agreement with certified values of reference materials and with standard methods at 95% confidence level.

Mechanical behaviour of strain aged dual phase steels

Dual phase steels, characterised by good formability and excellent surface finish, are suitable for applications where processing involves cold deformation. In this context an investigation has been conducted into the cold deformation aging susceptibility of carbon steel API-5L-B and microalloyed steel API-5L-X52, both with dual phase microstructures. Changes in mechanical properties such as phase microhardness, ultimate tensile strength, and yield strength in both types of steel were observed at aging temperatures of 25, 80, and 150°C. This aging is associated with dislocation structures formed on ferrite grains in the vicinity of ferrite/martensite interfaces during intercritical treatments, which become preferential sites for solute atom diffusion. © 1999 IoM Communications Ltd.

Optimization of the mechanical properties of low-carbon steels by formation of a multiphase microstructure

In this work five methods of heat treatments are investigated in order to obtained convenient volume fractions of ferrite, bainite, martensite and retained austenite, starting with a low carbon steel and seeking the distinction of the phases, through optical microscopy. Specific chemical etching is improved. The results in tensile and fatigue tests were accomplished and the results were related with the microstructural parameters. The results show that the mechanical properties are closely related with the phases, grains size and the phases morphology. Copyright © 2001 Society of Automotive Engineers, Inc.

Production and heat treatment of cast graphitic steels with additions of niobium

The optimal combination of the mechanical characteristics of austempered spheroidal graphitic cast steel together with modern casting techniques yielded an economically promising product. The maximum potential of the usage of these steels is related to fabrication and characterization techniques, among which, one of the most important is the cooling diagram (TTT curve). In this work, 3 heats of graphitic steels with the following nominal compositions were cast: 1.0 % C, 2.3 % Si, 0.4 % Mn, and with niobium contents of. 0.0 %, 0.5 % and 1.0 %. TTT curves were determined by dilatometric testing and test specimens of these steels were austempered. The samples were then characterized by hardness testing and optical and SEM microscopy. Tensile, impact (no notch) and wear testing were also performed. The addition of niobium produced significant alterations in the TTT diagrams. Increasing niobium content moves the pearlite transformation nose to the right and the bainitic transformation nose to the left. Tensile strength of these alloys was high, in the range of 1700 MPa and impact values were around of 45 Joules for alloy with 1 % Nb, 49 Joules for alloy with 0.5 % Nb and fracture did not occur for the alloy without the addition of Nb.

Production and heat treatment of cast graphitic steels with additions of niobium

The optimal combination of the mechanical characteristics of austempered spheroidal graphitic cast steel together with modern casting techniques yielded an economically promising product. The maximum potentiality of the usage of these steels is related to fabrication and characterization techniques, among which, one of the most important is the cooling diagram (TTT curve). In this work, 3 heats of graphitic steels with the following nominal compositions were cast: 1.0%C, 2.3%Si, 0.4% Mn, and with niobium contents of 0.0%, 0.5% and 1.0%. TTT curves were determined by dilatometric testing and test specimens of these steels were austempered. The samples were then characterized by hardness testing and optical and SEM microscopy. Tensile, impact (no notch) and wear testing were also performed. The addition of niobium produced significant alterations in the TTT diagrams. Increasing niobium content moves the pearlite transformation nose to the right and the bainitic transformation nose to the left. Tensile strength of these alloys was high, in the range of 1700 MPa and impact values were around of 45 Joules for alloy with 1% Nb, 49 Joules for alloy with 0.5% Nb and fracture did not occur for the alloy without the addition of Nb.

Grinding of hardened steels using optimized cooling

Grinding - the final machining process of a workpiece - requires large amounts of cutting fluids for the lubrication, cooling and removal of chips. These fluids are highly aggressive to the environment. With the technological advances of recent years, the worldwide trend is to produce increasingly sophisticated components with very strict geometric and dimensional tolerances, good surface finish, at low costs, and particularly without damaging the environment. The latter requirement can be achieved by recycling cutting fluids, which is a costly solution, or by drastically reducing the amount of cutting fluids employed in the grinding process. This alternative was investigated here by varying the plunge velocity in the plunge cylindrical grinding of ABNT D6 steel, rationalizing the application of two cutting fluids and using a superabrasive CBN (cubic boron nitride) grinding wheel with vitrified binder to evaluate the output parameters of tangential cutting force, acoustic emission, roughness, roundness, tool wear, residual stress and surface integrity, using scanning electron microscopy (SEM) to examine the test specimens. The performance of the cutting fluid, grinding wheel and plunge velocity were analyzed to identify the best machining conditions which allowed for a reduction of the cutting fluid volume, reducing the machining time without impairing the geometric and dimensional parameters, and the surface finish and integrity of the machined components.

Microstructural and electrochemical characterization of friction stir welded duplex stainless steels

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

MICROSTRUCTURAL CHARACTERIZATION OF DUAL AND MULTIPHASE STEELS APPLIED TO AUTOMOTIVE INDUSTRY

TRIP (Transformation Induced Plasticity) and DP (Dual-Phase) steels are written in a new series of steels which present excellent mechanical properties. As for microstructure aspect, TRIP steels consist on a ferrite matrix with a second phase dispersion of other constituents, such as bainite, martensite and retained austenite, while dual-phase steels consist on martensite dispersion in a ferrite matrix. In order to identify the different microconstituents present in these materials, microstructure characterization techniques by optical microscopy (using different etchants: LePera, Heat-Tinting and Nital) and scanning electron microscopy were carried out. This being so, microstructures were correlated with mechanical properties of materials, determined by means of tensile tests. It is concluded that steels assisted by TRIP effect have a strength and elongation relation higher than the dual-phase one. With microstructure characterization, it was observed phases present in these materials microstructure.