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.

Robots, intencionalidade e inteligência artificial

O artigo aborda problemas filosóficos relativos à natureza da intencionalidade e da representação mental. A primeira parte apresenta um breve histórico dos problemas, percorrendo rapidamente alguns episódios da filosofia clássica e da filosofia contemporânea. A segunda parte examina o Chinese Room Argument (Argumento do Quarto do Chinês) formulado por J. Searle. A terceira parte desenvolve alguns argumentos visando mostrar a inadequação do modelo funcionalista de mente na construção de robots. A conclusão (quarta parte) aponta algumas alternativas ao modelo funcionalista tradicional, como, por exemplo, o conexionismo.

Artificial neural networks for machining processes surface roughness modeling

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Mechanistic approach to predict real machining time for milling free-form geometries applying high feed rate

An accurate estimate of machining time is very important for predicting delivery time, manufacturing costs, and also to help production process planning. Most commercial CAM software systems estimate the machining time in milling operations simply by dividing the entire tool path length by the programmed feed rate. This time estimate differs drastically from the real process time because the feed rate is not always constant due to machine and computer numerical controlled (CNC) limitations. This study presents a practical mechanistic method for milling time estimation when machining free-form geometries. The method considers a variable called machine response time (MRT) which characterizes the real CNC machine's capacity to move in high feed rates in free-form geometries. MRT is a global performance feature which can be obtained for any type of CNC machine configuration by carrying out a simple test. For validating the methodology, a workpiece was used to generate NC programs for five different types of CNC machines. A practical industrial case study was also carried out to validate the method. The results indicated that MRT, and consequently, the real machining time, depends on the CNC machine's potential: furthermore, the greater MRT, the larger the difference between predicted milling time and real milling time. The proposed method achieved an error range from 0.3% to 12% of the real machining time, whereas the CAM estimation achieved from 211% to 1244% error. The MRT-based process is also suggested as an instrument for helping in machine tool benchmarking.

Analysis of diametrical wear of grinding wheel and roundness errors in the machining of steel VC 131

Due to the high industrial competitiveness, the rigorous laws of environmental protection, the necessary reduction of costs, the mechanical industry sees itself forced to worry more and more with the refinement of your processes and products. In this context, can be mentioned the need to eliminate the roundness errors that appear after the grinding process. This work has the objective of verifying if optimized nozzles for the application of cutting fluid in the grinding process can minimize the formation of the roundness errors and the diametrical wear of grinding wheel in the machining of the steel VC 131 with 60 HRc, when compared to the conventional nozzles. These nozzles were analyzed using two types of grinding wheels and two different cutting fluids. Was verified that the nozzle of 3mm of diameter, integral oil and the CBN grinding wheel, were the best options to obtain smaller roundness errors and the lowest diametrical wears of grinding wheels.

Autonomous mobile robots designing for the medical trash collector task

This paper describes the UNESP robotic team in the medical trash collector task, proposed on the 5 rd IEEE Latin American Robots Competition in the LEGO category. We present our understanding of the task and discuss the proposed solution, focusing on the mechanical and computational issues of the robots. The mechanics is based on rigid body capability of transforming rotational into curvilinear movement. With respect to the computational control, the system is modeled as a reactive system with sequential transition of behaviors. A state-machine is proposed to allow this transition, and the synchronization of robotic states is guaranteed by the communication system. The proposed approach has shown itself capable of dealing with the high difficulty degree of this cooperative task. ©2006 IEEE.

Conception of wheeled mobile robots with reconfigurable control using integrate prototyping

With the fast innovation of the hardware and software technologies using rapid prototyping devices, with application in the robotics and automation, more and more it becomes necessary the development of applications based on methodologies that facilitate future modifications, updates and enhancements in the original projected system. This paper presents a conception of mobile robots using rapid prototyping, distributing the several control actions in growing levels of complexity and using resources of reconfigurable computing proposal oriented to embed systems implementation. Software and the hardware are structuralized in independents blocks, with connection through common bus. The study and applications of new structures control that permits good performance in relation to the parameter variations. This kind of controller can be tested on different platform representing the wheeled mobile robots using reprogrammable logic components (FPGA). © 2006 IEEE.

Finite element analysis of warpage in laminated aluminium alloy plates for machining of primary aeronautic parts

The aim of this paper consists in presenting a method of simulating the warpage in 7xxx series aluminium alloy plates. To perform this simulation finite element software MSC.Patran and MSC.Marc were used. Another result of this analysis will be the influence on material residual stresses induced on the raw material during the rolling process upon the warpage of primary aeronautic parts, fabricated through machining (milling) at Embraer. The method used to determinate the aluminium plate residual stress was Layer Removal Test. The numerical algorithm Modified Flavenot Method was used to convert layer removal and beam deflection in stress level. With such information about the level and profile of residual stresses become possible, during the step that anticipate the manufacturing to incorporate these values in the finite-element approach for modelling warpage parts. Based on that warpage parameter surely the products are manufactured with low relative vulnerability propitiating competitiveness and price. © 2007 American Institute of Physics.

A framework for learning in humanoid simulated robots

One of the most important characteristics of intelligent activity is the ability to change behaviour according to many forms of feedback. Through learning an agent can interact with its environment to improve its performance over time. However, most of the techniques known that involves learning are time expensive, i.e., once the agent is supposed to learn over time by experimentation, the task has to be executed many times. Hence, high fidelity simulators can save a lot of time. In this context, this paper describes the framework designed to allow a team of real RoboNova-I humanoids robots to be simulated under USARSim environment. Details about the complete process of modeling and programming the robot are given, as well as the learning methodology proposed to improve robot's performance. Due to the use of a high fidelity model, the learning algorithms can be widely explored in simulation before adapted to real robots. © 2008 Springer-Verlag Berlin Heidelberg.

Virtual simulator for mobile robots navigation systems

This paper presents the virtual environment implementation for project simulation and conception of supervision and control systems for mobile robots, that are capable to operate and adapting in different environments and conditions. This virtual system has as purpose to facilitate the development of embedded architecture systems, emphasizing the implementation of tools that allow the simulation of the kinematic conditions, dynamic and control, with real time monitoring of all important system points. For this, an open control architecture is proposal, integrating the two main techniques of robotic control implementation in the hardware level: systems microprocessors and reconfigurable hardware devices. The implemented simulator system is composed of a trajectory generating module, a kinematic and dynamic simulator module and of a analysis module of results and errors. All the kinematic and dynamic results shown during the simulation can be evaluated and visualized in graphs and tables formats, in the results analysis module, allowing an improvement in the system, minimizing the errors with the necessary adjustments optimization. For controller implementation in the embedded system, it uses the rapid prototyping, that is the technology that allows, in set with the virtual simulation environment, the development of a controller project for mobile robots. The validation and tests had been accomplish with nonholonomics mobile robots models with diferencial transmission. © 2008 IEEE.

Environment mapping for mobile robots navigation using hierarchical neural network and omnivision

Autonomous robots must be able to learn and maintain models of their environments. In this context, the present work considers techniques for the classification and extraction of features from images in joined with artificial neural networks in order to use them in the system of mapping and localization of the mobile robot of Laboratory of Automation and Evolutive Computer (LACE). To do this, the robot uses a sensorial system composed for ultrasound sensors and a catadioptric vision system formed by a camera and a conical mirror. The mapping system is composed by three modules. Two of them will be presented in this paper: the classifier and the characterizer module. The first module uses a hierarchical neural network to do the classification; the second uses techiniques of extraction of attributes of images and recognition of invariant patterns extracted from the places images set. The neural network of the classifier module is structured in two layers, reason and intuition, and is trained to classify each place explored for the robot amongst four predefine classes. The final result of the exploration is the construction of a topological map of the explored environment. Results gotten through the simulation of the both modules of the mapping system will be presented in this paper. © 2008 IEEE.

α-SiAION: Development and machining test on gray cast iron

The α-SiAlON ceramic cutting tool insert is developed. Silicon nitride and additives powders are pressed and sintered in the form of cutting tool inserts at temperature of 1900 °C. The physics and mechanical properties of the inserts like green density, weight loss, relative density, hardness and fracture toughness are evaluated. Machining studies are conducted on grey cast iron workpiece to evaluate the performance of α-SiAlON ceramic cutting tool. In the paper the cutting tool used in higher speed showed an improvement in the tribological interaction between the cutting tools and the grey cast iron workpiece resulted in a significant reduction of flank wear and roughness, because of better accommodation and the presence of the graphite in gray cast iron. The above results are discussed in terms of their affect at machining parameters on gray cast iron.

Turning of compacted graphite iron using commercial tiN coated Si 3N4 under dry machining conditions

Due to their high hardness and wear resistance Si3N4 based ceramics are one of the most suitable cutting tool materials for machining hardened materials. Therefore, their high degree of brittleness usually leads to inconsistent results and sudden catastrophic failures. Improvement of the functional properties these tools and reduction of the ecological threats may be accomplished by employing the technology of putting down hard coatings on tools in the state-of-the-art PVD processes, mostly by improvement of the tribological contact conditions in the cutting zone and by eliminating the cutting fluids. However in this paper was used a Si3N4 based cutting tool commercial with a layer TiN coating. In this investigation, the performance of TiN coating was assessed on turning used to machine an automotive grade compacted graphite iron. As part of the study were used to characterise the performance of cutting tool, flank wear, temperature and roughness. The results showed that the layer TiN coating failed to dry compacted graphite iron under aggressive machining conditions. However, using the measurement of flank wear technique, the average tool life of was increased by VC=160 m/min.The latter was also observed using a toolmakers microscope and scanning electron microscopy (SEM).

Properties advanced of the silicon nitride based ceramics and recent performance on automotive parts manufacture by machining process: Advanced Ceramics, demand Forecast

Automotive parts manufacture by machining process using silicon nitride-based ceramic tool development in Brazil already is a reality. Si 3N4-based ceramic cutting tools offer a high productivity due to their excellent hot hardness, which allows high cutting speeds. Under such conditions the cutting tool must be resistant to a combination of mechanical, thermal and chemical attacks. Silicon nitride based ceramic materials constitute a mature technology with a very broad base of current and potential applications. The best opportunities for Si3N 4-based ceramics include ballistic armor, composite automotive brakes, diesel particulate filters, joint replacement products and others. The goal of this work was to show latter advance in silicon nitride manufacture and its recent evolution on machining process of gray cast iron, compacted graphite iron and Ti-6Al-4V. Materials characterization and machining tests were analyzed by X-Ray Diffraction, Scanning Electron Microscopy, Vickers hardness and toughness fracture and technical norm. In recent works the authors has been proved to advance in microstructural, mechanical and physic properties control. These facts prove that silicon nitride-based ceramic has enough resistance to withstand the impacts inherent to the machining of gray cast iron (CI), compacted graphite iron (CGI) and Ti-6Al-4V (6-4). Copyright © 2008 SAE International.

Robots en la industria

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