On the numerical simulation of machining processes

Numerical simulation of machining processes can be traced back to the early seventies when finite element models for continuous chip formation were proposed. The advent of fast computers and development of new techniques to model large plastic deformations have favoured machining simulation. Relevant aspects of finite element simulation of machining processes are discussed in this paper, such as solution methods, material models, thermo-mechanical coupling, friction models, chip separation and breakage strategies and meshing/re-meshing strategies.

Application of cutting fluids in machining processes

In the last decade a lot has been discussed about the suitability of using cutting fluid in abundance to cool and lubricate machining processes. The use of cutting fluid generally causes economy of tools and it becomes easier to keep tight tolerances and to maintain workpiece surface properties without damages. In the other hand, it brings also some problems, like fluid residuals and human diseases. Because of them some alternatives has been sought to minimise or even avoid the use of cutting fluid in machining operations. Some of these alternatives are dry cutting and cutting with minimum quantity of fluid (MQF). The main goal of this work is to discuss these tendencies. Therefore, topics like kinds and methods of applications of modern cutting fluids and what are new in this area will unavoidably be considered. MQF and dry cutting techniques, their applications and where it is not possible to apply them will also be focused. To exemplify the topics, this work will describe some of the researches been developed in two important Brazilian Universities: State University of Campinas (UNICAMP) and Federal University of Uberlândia (UFU).

Influence of duty factor on the die-sinking Electrical Discharge Machining of high-strength aluminum alloy under rough machining

The use of high-strength aluminium alloys as material for injection molding tools to produce small and medium batches of plastic products as well as prototyping molds is becoming of increasing demand by the tooling industry. These alloys are replacing the traditional use of steel in the cases above because they offer many advantages such as very high thermal conductivity associated with good corrosion and wear resistance presenting good machinability in milling and electrical discharge machining operations. Unfortunately there is little technological knowledge on the Electrical Discharge Machining (EDM) of high-strength aluminium alloys, especially about the AMP 8000 alloy. The duty factor, which means the ratio between pulse duration and pulse cycle time exerts an important role on the performance of EDM. This work has carried out an experimental study on the variation of the duty factor in order to analyze its influence on material removal rate and volumetric relative wear under roughing conditions of EDM process. The results showed that high values of duty factor are possible to be applied without bringing instability into the EDM process and with improvement of material removal rate and volumetric relative wear.

Analysis of open CNC architecture for machine tools

The evolution of digital circuit technology, leadind to higher speeds and more reliability allowed the development of machine controllers adapted to new production systems (e.g., Flexible Manufacturing Systems - FMS). Most of the controllers are developed in agreement with the CNC technology of the correspondent machine tool manufacturer. Any alterations or adaptation of their components are not easy to be implemented. The machine designers face up hardware and software restrictions such as lack of interaction among system's elements and impossibility of adding new function. This is due to hardware incompatibility and to software not allowing alterations in the source program. The introduction of open architecture philosophy propitiated the evolution of a new generation of numeric controllers. This brought the conventional CNC technology to the standard IBM - PC microcomputer. As a consequence, the characteristics of the CNC (positioning) and the microcomputer (easy of programming, system configuration, network communication etc) are combined. Some researchers have addressed a flexible structure of software and hardware allowing changes in the hardware basic configuration and all control software levels. In this work, the development of open architecture controllers in the OSACA, OMAC, HOAM-CNC and OSEC architectures is described.

Bionanocompósitos preparados por incorporação de nanocristais de celulose em polímeros biodegradáveis por meio de evaporação de solvente, automontagem ou eletrofiação

This review reports the preparation and characterization of bionanocomposites based on biodegradable polymers reinforced with cellulose nanocrystals (CNC) described in the literature. The outstanding potential of cellulose nanocrystals as reinforcement fillers of biodegradable polymers is presented with an emphasis on the solution casting process, which is an appropriate method to investigate the physico-chemical effects of the incorporation of CNC into the polymeric matrices. Besides solution casting, other small scale methods such as electrospinning and layer-by-layer are also covered.

Genes diferentes podem conferir resistência ao Cowpea severe mosaic virus em caupi

O caupi (Vigna unguiculata) é uma importante leguminosa cultivada principlamente por pequenos agricultores da região Nordeste. Doenças ocasionadas por vírus podem constituir o principal fator limitante da produção do caupi, destacando-se, nesse aspecto, o mosaico severo, causado pelo Cowpea severe mosaic virus (CpSMV), família Comoviridae, gênero Comovirus. A resistência tem sido considerada como a melhor alternativa no controle dessa virose e diversas fontes promissoras têm sido relatadas, como as cultivares Macaibo e CNC 0434, e a linhagem L254.008. As investigações sobre a base genética da resistência ao CpSMV nesses materiais têm conduzido a resultados semelhantes, sendo a resistência herdada como uma característica monogênica recessiva. No entanto, até então, nenhum trabalho havia investigado o alelismo dos genes de resistência dessas fontes. No presente trabalho foram realizados estudos visando esclarecer essa questão nas três fontes de resistência; 'Macaibo', 'CNC0434' e L254.008. Plantas dos referidos genótipos foram cruzadas de maneira direta e recíproca originando seis populações F1 e F2. Inoculações controladas dessas populações com o isolado CpSMV-Re1 permitiram concluir que o gene de resistência de 'Macaibo' é o mesmo de 'CNC-0434', distinto daquele encontrado na linhagem L254.008.

Caracterização da fusão caruncular em gestações naturais e de conceptos bovinos clonados

O objetivo deste trabalho foi comparar as fusões carunculares em gestações de conceptos não clonados (CNC) e conceptos clonados (CC). Os CNC foram divididos segundo o período de gestação em Grupo I (2-3 meses, n=9), Grupo II (4-6 meses, n=9), Grupo III (7-8 meses, n=10) e Grupo IV (9 meses, n=7). Os CC formaram o Grupo V (9 meses, n=4). As carúnculas foram observadas macroscopicamente (número e dimensões: comprimento, largura e altura), microscopicamente e submetidas à análise estatística (5% de significância). Observaram-se três tipos de fusões carunculares macroscópicas: ovais (morfologicamente normais); duas carúnculas adjacentes unidas e do tipo lobuladas, caracterizadas por regiões com várias carúnculas unidas apresentando falsa fusão ou deformação do parênquima caruncular. O comprimento das carúnculas foi de 1,55±0,57; 2,45±0,55; 4,66±2,00 e 5,72±1,90cm para os Grupos I, II, III e IV, respectivamente. Quanto à altura, as carúnculas apresentaram um crescimento linear durante a gestação e foram de 0,40±0,15; 0;57±0,21; 1,00±0,48 e 1,80±0,91cm, para os respectivos Grupos I, II, III e IV. A largura das carúnculas foi semelhante entre os Grupos I e II (0,97±0,30 e 1,42±0,71cm) e os Grupos III e IV (2,68±1,22 e 3,52±1,16cm). Quando o Grupo V foi comparado ao Grupo IV, as carúnculas do Grupo V apresentaram maior comprimento (5,72±1,90 vs. 7,88±2,13cm) e largura (3,52±1,16 vs. 4,93±1,46cm), porém foram semelhantes em altura (1,80±0,91 e 2,25±0,67cm). Verificou-se que em gestações de CC, as carúnculas apresentaram maior desenvolvimento que em gestações de CNC. As carúnculas fusionadas apresentaram medidas estatisticamente semelhantes às isoladas em todos os parâmetros e grupos. Sob microscopia de luz, observou-se a formação de um eixo estromal, da base da carúncula ao ápice da fissura fusional, de constituição histológica semelhante ao estroma endometrial. Também foram ineditamente definidos três formatos microscópicos: fusão propriamente dita com eixo único, evidente abaixo da fissura fusional; pseudofusão com eixo duplo em forma de "H" e a falsa fusão com ausência do eixo. Os dois primeiros formatos referem-se às carúnculas ovais e lobuladas e o último à falsa fusão com deformação do parênquima caruncular. O eixo fusional aumentou de tamanho durante a gestação entre os Grupos I, II, III e IV. O Grupo V apresentou maior comprimento e largura de eixo quando comparado ao Grupo IV. Sendo assim, em gestações de CC a destruição do epitélio lateral das carúnculas está associada a uma incompetência na interdigitação materno-fetal, que comprometem a fusão cotiledonária. Sugere-se que, em gestações provenientes de CC, o aumento do tamanho das fusões carunculares possivelmente associa-se a um mecanismo compensatório para as trocas metabólicas entre mãe e feto, em razão do menor número de carúnculas isoladas.

Critical aspects on the behavior of material from the mechanical tool-workpiece interaction in single point diamond turning

Some material aspects such as grain size, purity and anisotropy exert an important influence on surface quality, especially in single point diamond turning. The aim of this paper is to present and discuss some critical factors that can limit the accuracy of ultraprecision machining of non-ferrous metals and to identify the effects of them on the cutting mechanism with single point diamond tools. This will be carried out through observations of machined surfaces and chips produced using optical and scanning electron microscopy. Solutions to reduce the influence of some of these limiting factors related with the mechanism of generation of mirror-like surfaces will be discussed.

Investigation on diamond turning of silicon crystal - generation mechanism of surface cut with worn tool

This paper discusses the effect of tool wear on surface finish in single-point diamond turning of single crystal silicon. The morphology and topography of the machined surface clearly show the type of cutting edge wear reproduced onto the cutting grooves. Scanning electron microscopy is used in order to correlate the cutting edge damage and microtopography features observed through atomic force microscopy. The possible wear mechanisms affecting tool performance and surface generation during cutting are also discussed. The zero degree rake angle single point diamond tool presented small nicks on the cutting edge. The negative rake angle tools presented more a type of crater wear on the rake face. No wear was detected on flank face of the diamond tools.