Bizikletako aurreko abatzaren mekanizaziorako cam bidezko programazioa

[EU]Lan honek bizikletako aurreko gurpileko abatz baten CAM edo CNC programazioa egitean datza, honen bidez erremintaren ibilbidea deskribatuz piezaren CAD eredutik abiatuz. Hasteko, zenbakizko kontrolak izan duen eboluzioa eta garrantzia azaltzen da. Ondoren, abatzaren funtzionamenduaren deskribapena egin da, bere osagaiak eta izan behar dituen ezaugarriak aztertuz. Gainera, fabrikazio prozesu ezberdinen analisia egin da, bakoitzaren abantaila eta desabantailak azpimarratuz. Azkenik, zenbakizko kontrolaren inguruan bereganatutako ezagutzak aplikatu dira CAM programa batean abatz baten mekanizazioa programatuz. Honez gain, erabilitako CAM programaren erabilera azaltzen da.

Programación de control numérico de un pedal de batería mediante el software Surfcam.

[ES]El objetivo de este trabajo es programar y mecanizar un molde de inyección de aluminio, con el objetivo de obtener un pedal de batería. Para ello, previamente se necesitará diseñar en CAD el molde, para posteriormente exportarlo al programa Surfcam V4.0, donde se definirán las trayectorias de las herramientas teniendo en cuenta su geometría. Una vez definidas en el programa, éste se ejecutará en un centro de mecanizado sobre un tocho de aluminio.

Diseño y fabricación de un electrodo para electroerosión por penetración mediante fabricación aditiva.

[ES]Este trabajo pretende dar solución a la fabricación de los electrodos utilizados en el proceso de la electroerosión, los cuales presentan numerosos requisitos a los que los electrodos actuales no dan respuesta. Por ello, se propone utilizar un material de bajo coste como núcleo y recubrirlo con una fina capa de cobre mediante laser cladding. De esta forma, se reduce el coste del electrodo manteniendo sus propiedades y se posibilita la creación de geometrías complejas.

Fabricación de piñón para motocicleta de competición. Prototipo.

[ES]Este trabajo fin de grado consiste en la fabricación de un piñón de motocicleta de competición, la cual está destinada a participar en Moto Student, una competición entre universidades de todo el mundo. Se procede a realizar un estudio de las alternativas existentes, para finalizar eligiendo una técnica novedosa y atractiva como la electroerosión por hilo. Además, se tomarán otras decisiones también importantes como el material a utilizar o los procesos de mecanizado previos a la electroerosión que cumplan las exigencias de diseño de una forma óptima y económicamente viable.

Desarrollo de técnicas de fresado en cinco ejes de engranajes espiro cónicos y posterior metrología.

[ES]El presente Trabajo Fin de Grado tiene como objetivo contribuir al desarrollo de diferentes técnicas de fresado de engranajes espiro cónicos mediante fresadoras genéricas de cinco ejes. El proyecto estará dividido en varias partes que incluirán: el diseño de la geometría de las piezas a mecanizar, el propio proceso de manufactura y su posterior metrología. Durante el transcurso del curso 2014-2015 se documentará y participará activamente en el desarrollo de dichas técnicas de fresado. Proceso que será dirigido por Álvaro Álvarez, doctorando del departamento de Mecánica de la Escuela Superior de Ingeniería de Bilbao. El objetivo principal es llegar a ser capaz de obtener piezas de gran complejidad en su diseño y proceso de fabricación, dentro de los márgenes de calidad exigidos por las normas pertinentes y mediante un proceso novedoso y competitivo a nivel internacional.

Diseño y programación del control numérico para el mecanizado del escudo del Real Madrid.

[ES]El objetivo de este proyecto es programar el control numérico para la mecanización del escudo del Real Madrid. Para conseguir esto, primero es necesario aprender cómo funcionan los programas que se van a usar. Después de esto se va a crear el archivo CAD, usando el programa Solid Edge. Luego, usando el programa SurfCam Velocity 4.0 se programará el control numérico necesario para la fabricación del escudo.

Caracterización del error en el corte de desbaste de trayectorias circulares mediante WEDM.

[ES]En la actualidad el proceso de mecanizado mediante electroerosión por hilo (WEDM) posee varias problemáticas a la hora de la ejecución de los cortes para producir diferentes formas, ya sean esquinas, radios de redondeo o de acuerdo y por último la realización de círculos. Es por ello por lo que se elabora el presente trabajo cuya finalidad es llegar a caracterizar los errores cometidos en el corte de desbaste de probetas con trayectorias circulares y tecnología estándar. De esta manera se podrá cuantificar las desviaciones que se producen en las piezas en función del espesor y de sus radios. Toda la información obtenida en el trabajo permitirá una futura actuación en diversos parámetros máquina, elaborando nuevas tecnologías o bien poder mitigarlos realizando correcciones geométricas, ajustando sus tolerancias.

Análisis del mecanizado de un molde para la fabricación de un logo deportivo.

[ES]Las compañías líderes del mundo textil compiten cada día por ser las número 1 en cuanto a ventas se refiere. Para ello, son necesarias diferentes estrategias de venta. Una de ellas es la adición de diferentes adornos de plástico que hacen que el comprador se fije en sus productos. Por otro lado, las tecnologías de mecanizado están en pleno avance y la fabricación de piezas o moldes es cada vez más eficiente. Por eso en este trabajo se quiere analizar y estudiar la fabricación de un molde de inyección de plástico con el logotipo de una de las marcas más famosas en el mundo, Adidas. Se ha de llevar a cabo un estudio de los posibles materiales a utilizar para el molde, así como, las distintas alternativas de mecanizado que hoy en día se emplean para este tipo de procesos. Además, los avances en los distintos programas CAD/CAM son de especial ayuda para este tipo de trabajos. Estos programas son capaces de trazar las trayectorias más eficientes a la hora de mecanizar distintos tipos de piezas y postprocesar la programación de dichas trayectorias para luego ser introducidas en los centros CNC.

Virtual Sensors for On-line Wheel Wear and Part Roughness Measurement in the Grinding Process

Grinding is an advanced machining process for the manufacturing of valuable complex and accurate parts for high added value sectors such as aerospace, wind generation, etc. Due to the extremely severe conditions inside grinding machines, critical process variables such as part surface finish or grinding wheel wear cannot be easily and cheaply measured on-line. In this paper a virtual sensor for on-line monitoring of those variables is presented. The sensor is based on the modelling ability of Artificial Neural Networks (ANNs) for stochastic and non-linear processes such as grinding; the selected architecture is the Layer-Recurrent neural network. The sensor makes use of the relation between the variables to be measured and power consumption in the wheel spindle, which can be easily measured. A sensor calibration methodology is presented, and the levels of error that can be expected are discussed. Validation of the new sensor is carried out by comparing the sensor's results with actual measurements carried out in an industrial grinding machine. Results show excellent estimation performance for both wheel wear and surface roughness. In the case of wheel wear, the absolute error is within the range of microns (average value 32 mu m). In the case of surface finish, the absolute error is well below R-a 1 mu m (average value 0.32 mu m). The present approach can be easily generalized to other grinding operations.

反射率对入射角扫描测定单轴晶体的折射率

通过分析波矢沿任意方向的单轴晶体的折射率,在光轴位于入射面内时,给出了入射光分别为s光和p光的反射率拟合函数。利用改进的反射率扫描仪,测量了CaCO3晶体的s光和p光反射率随入射角变化情况,由理论拟合获得单轴晶体的两个主折射率,分别为no=1.6559和ne=1.4851。这种方法不需要对样品进行加工,其精度达到0.0001。另外,对于晶体光轴未知的情况,采用改进的布儒斯特技术分别测出三个晶体表面的布儒斯特角,由此可以确定光轴的方向。

Caracterização microestrutural e análise de tensões residuais pelo método do furo cego em tubo de seção quadrada com costura.

Tensões residuais são uma das principais causas de falhas em componentes mecânicos submetidos a processos de fabricação. O objetivo do trabalho foi medir as tensões residuais presentes em um tubo quadrado soldado por resistência elétrica de alta frequência e caracterizar microestruturalmente o seu material. Para a caracterização, foram utilizadas técnicas de microscopia óptica (MO), microscopia eletrônica de varredura (MEV) e análise química quantitativa. Para a medição das tensões residuais, foi utilizado o método do furo cego, baseado na norma ASTM E837-08, onde rosetas (strain-gages) são coladas à peça para medir as deformações geradas devido à usinagem de um pequeno furo no local de medição. As deformações foram associadas às tensões residuais através de equações baseadas na Lei de Hooke. A caracterização revelou uma microestrutura composta basicamente de ferrita e perlita, típica de aços com baixo teor de carbono, corroborando com a especificação fornecida pelo fabricante. As tensões residuais encontradas foram trativas e mostraram-se elevadas, com alguns valores acima do limite de escoamento do material.

INFLUENCE OF ATMOSPHERIC COMPOSITION ON THE ABRASIVE WEAR OF TITANIUM AND Ti-6Al-4V.

A pin-on-disc apparatus has been used to investigate the wear and friction (sliding force) behavior of metals on bonded silicon carbide and alumina papers under conditions of controlled atmospheric composition. The wear rates of both commercial purity titanium and the alloy Ti-6%Al-4%V tested in air were found to remain constant with time, in contrast with the behavior of other metals tested under similar conditions, which exhibited a progressive decrease in wear rate with increasing number of passes along the same track. It is proposed that the concentration of interstitial nitrogen and oxygen in the worn metal surface, which largely determines its mechanical properties, strongly influences both the ductility of the abraded material and the force of adhesion between the metal and the abrasive particles. Parallels are drawn between abrasive wear and machining to illustrate the importance of oxygen at the interface between workpiece and tool surfaces.

Active glass-polymer superlattice structure for photonic integration.

We propose an all-laser processing approach allowing controlled growth of organic-inorganic superlattice structures of rare-earth ion doped tellurium-oxide-based glass and optically transparent polydimethyl siloxane (PDMS) polymer; the purpose of which is to illustrate the structural and thermal compatibility of chemically dissimilar materials at the nanometer scale. Superlattice films with interlayer thicknesses as low as 2 nm were grown using pulsed laser deposition (PLD) at low temperatures (100 °C). Planar waveguides were successfully patterned by femtosecond-laser micro-machining for light propagation and efficient Er(3+)-ion amplified spontaneous emission (ASE). The proposed approach to achieve polymer-glass integration will allow the fabrication of efficient and durable polymer optical amplifiers and lossless photonic devices. The all-laser processing approach, discussed further in this paper, permits the growth of films of a multitude of chemically complex and dissimilar materials for a range of optical, thermal, mechanical and biological functions, which otherwise are impossible to integrate via conventional materials processing techniques.

Micromachining of glassy carbon toolsets for micro embossing applications

Laser micro machining is fast gaining popularity as a method of fabricating micro scale structures. Lasers have been utilised for micro structuring of metals, ceramics and glass composites and with advances in material science, new materials are being developed for micro/nano products used in medical, optical, and chemical industries. Due to its favourable strength to weight ratio and extreme resistance to chemical attack, glassy carbon is a new material that offers many unique properties for micro devices. The laser machining of SIGRADUR® G grade glassy carbon was characterised using a 1065 nm wavelength Ytterbium doped pulsed fiber laser. The laser system has a selection of 25 preset waveforms with optimised peak powers for different pulsing frequencies. The optics provide spot diameter of 40 μm at the focus. The effect of fluence, transverse overlap and pulsing frequency (as waveform) on glassy carbon was investigated. Depth of removal and surface roughness were measured as machining quality indicators. The damage threshold fluence was determined to be 0.29 J/cm2 using a pulsing frequency of 250 kHz and a pulse width of 18 ns (waveform 3). Ablation rates of 17 < V < 300 μm3/pulse were observed within a fluence range of 0.98 < F < 2.98 J/cm2. For the same fluence variation, 0.6 μm to 6.8 μm deep trenches were machined. Trench widths varied from 29 μm at lower fluence to 47 μm at the higher fluence. Square pockets, 1 mm wide, were machined to understand the surface machining or milling. The depth of removal using both waveform 3 and 5 showed positive correlation with fluence, with waveform 5 causing more removal than waveform 3 for the same fluence. Machined depths varied from less than 1 μm to nearly 40 μm. For transverse overlap variation using waveform 3, the best surface finish with Rz = 1.1 μm was obtained for fluence 0.792 J/cm2 for transverse overlap of 1 μm, 6 μm, and 9 μm at machined depths of 22.9 μm, 6.6 μm, and 4.6 μm respectively. For fluence of 1.426 J/cm2, the best surface finish with Rz = 1.2 μm was obtained for transverse overlap of 6 μm, and 9 μm at machined depths of 12.46 μm, and 8.6 μm respectively. The experimental data was compiled as machining charts and utilised for fabricating a micro-embossing glassy carbon master toolsets as a capability demonstration.

On the percussion drilling of SI using a 20W MOPA based YB fiber laser

A study on the nanosecond fiber laser interaction with silicon was performed experimentally for the generation of percussion drilled holes. Single pulse ablation experiments were carried out on mono crystalline 650μm thick Si wafers. Changes of the mass removal mechanism were investigated by varying laser fluence up to 68 J/cm2 and pulse duration from 50 ns to 200 ns. Hole width and depth were measured and surface morphology were studied using scanning electron microscopy (SEM) and optical interferometric profilometry (Veeco NT3300). High speed photography was also used to examine laser generated plasma expansion rates. The material removal rate was found to be influenced by the pulse energy, full pulse duration and pulse peak power. Single pulse ablation depth of 4.42 μm was achieved using a 200 ns pulse of 13.3 J/cm 2, giving a maximum machining efficiency of 31.86 μm per mJ. Holes drilled with an increased fluence but fixed pulse length were deeper, exhibited low recast, but were less efficient than those produced at a lower fluence. The increased peak power in this case led to high levels of plasma and vapour production. The expansion of which, results in a strong driving recoil force, an increase in the rate and volume of melt ejection, and cleaner hole formation. The experimental findings show that for efficient drilling at a given energy, a longer, lower peak power pulse is more desirable than a high peak power short pulse.