Dry grinding technology for automotive gears manufacturing: process modeling and optimization

The following thesis focused on the dry grinding process modelling and optimization for automotive gears production. A FEM model was implemented with the aim at predicting process temperatures and preventing grinding thermal defects on the material surface. In particular, the model was conceived to facilitate the choice of the grinding parameters during the design and the execution of the dry-hard finishing process developed and patented by the company Samputensili Machine Tools (EMAG Group) on automotive gears. The proposed model allows to analyse the influence of the technological parameters, comprising the grinding wheel specifications. Automotive gears finished by dry-hard finishing process are supposed to reach the same quality target of the gears finished through the conventional wet grinding process with the advantage of reducing production costs and environmental pollution. But, the grinding process allows very high values of specific pressure and heat absorbed by the material, therefore, removing the lubricant increases the risk of thermal defects occurrence. An incorrect design of the process parameters set could cause grinding burns, which affect the mechanical performance of the ground component inevitably. Therefore, a modelling phase of the process could allow to enhance the mechanical characteristics of the components and avoid waste during production. A hierarchical FEM model was implemented to predict dry grinding temperatures and was represented by the interconnection of a microscopic and a macroscopic approach. A microscopic single grain grinding model was linked to a macroscopic thermal model to predict the dry grinding process temperatures and so to forecast the thermal cycle effect caused by the process parameters and the grinding wheel specification choice. Good agreement between the model and the experiments was achieved making the dry-hard finishing an efficient and reliable technology to implement in the gears automotive industry.

Catchability and survival of the resources during fishing operation

The present Ph.D. thesis aims to test and evaluate by-catch reduction devices (BRDs) that minimize the retention of undersized fish and do not penalize revenues of the fishing industry. Considering that a fraction of fish that escape from fishing gear or that are rejected at the sea probably does not survive (unaccounted mortality), it is a major concern for sustainable fisheries management, as unaccounted mortality may lead to biased stock assessment since they will tend to underestimate fishing mortality and overestimate stock size. In this context, in the present Ph.D. thesis, the escape survival (i.e. survival of the fish escaped through the trawl net codend) of the Mullus barbatus Linnaeus 1758 and the discard survival (survival of fish rejected at the sea after being hauled on deck) of Trachurus trachurus were evaluated for the first time in the central Mediterranean Sea. In conclusion, the use of underwater lights in Mediterranean trawl fisheries should be carefully regulated through ad hoc measures that are currently lacking, to minimize the potential impacts of artificial light on some already overexploited stocks. Even if further works should be carried out in the future to test BRDs performances in different areas and seasons, the T90 50 mm codend and the Grid-T45 40 mm seem promising tools to reduce the catch of undersized individuals and contribute to mitigating the current overfishing of Parapenaeus longirostris and Merluccius merluccius. The escape survival of M. barbatus was high and thanks to an improved methodology the bias in the sampling was minimized. However, for improved stock assessment of M. barbatus, the experiment should be repeated to provide accurate escape mortality estimates. While the discard survival of T. trachurus was very low and according to the landing obligation (Reg. EU 1380/2013) all the juveniles of the species should be landed.