Analys av förvridning vid hålning av rör : Analysis of metal torsion in rotary piercing

Hålningsprocessen är det inledande bearbetningssteget vid varmvalsning av sömlösa rör. Det är en tvärvalsningsprocess i vilken ett cylindriskt ämne valsas mellan två dubbelkoniska val¬sar över en plugg. Valsarna är snedställda med en viss mat¬ningsvinkel, vilken ger upphov till en axiell drivkraft genom ver¬ket. Hela denna pro¬cess är roterande. Detta i kombination med bl.a. de koniska valsarna leder till en förvrid¬ning av röret, dvs. en tänkt rak linje på det ingå¬ende äm¬net övergår till en spiral efter genomförd valsning. Med föreliggande uppgift är målet att studera förvridningen genom teoretisk och experimen¬tell analys. Syftet med detta är dels att få fördjupad kunskap inom området och dels att ut¬veckla en modell för pre¬diktering av förvridningen.Det experimentella arbetet är utfört på ett stål av typ Ovako 280 (SS2142). Denna mjuka stål¬sort valdes i syfte att undvika värmebehandling innan provberedning. För att visuali¬sera för¬vridningen fräs¬tes ett rakt spår längs det ingående äm¬net och hål borrades mot symmetrilinjen. De praktiska undersökningarna utfördes direkt i den löpande produktionen. Genomförda beräkningar uppvisar en längsgående förvridningsvinkel som stämmer väl över¬ens med uppmätt värde. Detta är dock under antagandet att den tangentiella hastighetskoeffi¬cienten varierar linjärt utmed deformationszonen. För en mer utvecklad modell krävs en nog¬grannare analys av kontakten mellan vals/ämne eller en grundligt genomförd uppmätning av ämnets vinkelhastighet.

Tribology in Metal Working

This thesis focuses on the tribological performance of tool surfaces in two steel working operations, namely wire drawing and hot rolling. In all forming operations dimensions and surface finish of the products are of utmost importance. Forming basically includes three parts – forming conditions excluded – that may be changed; work material, tool and (possibly) lubricant. In the interface between work material and tool, the conditions are very aggressive with – generally or locally – high temperatures and pressures. The surfaces will be worn in various ways and this will change the conditions in the process. Consequently, the surface finish as well as the dimensions of the formed product may change and in the end, the product will not fulfil the requirements of the customer. Therefore, research and development in regard to wear, and consequently tribology, of the forming tools is of great interest. The investigations of wire drawing dies focus on coating adhesion/cohesion, surface characteristics and material transfer onto the coated steel both in laboratory scale as well as in the wire drawing process. Results show that it in wire drawing is possible to enhance the tribological performance of drawing dies by using a lubricant together with a steel substrate coated by a polished, dual-layer coating containing both hard and friction-lowering layers. The investigations of hot rolling work rolls focus on microstructure and hardness as well as cracking- and surface characteristics in both laboratory scale and in the hot strip mill. Results show that an ideal hot work roll material should be made up of a matrix with high hardness and a large amount of complex, hard carbides evenly distributed in the microstructure. The surface failure mechanisms of work rolls are very complex involving plastic deformation, abrasive wear, adhesive wear, mechanical and thermal induced cracking, material transfer and oxidation. This knowledge may be used to develop new tools with higher wear resistance giving better performance, lower costs and lower environmental impact.

Melhoria de desempenho na área de forjaria de uma empresa do ramo metal-mecânico utilizando uma ferramenta de estratégia de produção, o método GAP

Visando consolidar uma estratégia de produção, junto a uma empresa do ramo metalmecânico de Caxias do Sul, este trabalho implanta e analisa através de uma pesquisa-ação a utilização de um método de formulação de estratégia de produção seguindo a orientação de GAP ou lacuna. O trabalho foi desenvolvido no setor de forjaria e buscou a melhoria dos critérios competitivos junto aos seus clientes. Após descrever o processo de implantação desse método e avaliar seus resultados, é traçado um plano de ação a ser aplicado, evidenciando seus resultados. Como resultados pode-se citar que qualidade como critério competitivo não depende apenas dos sistemas de garantia mas também de uma abordagem mais próxima da área de recursos humanos.

Acumulação tecnológica e aprimoramento de performance competitiva: evidências de diferenças e similaridades e médias empresas do setor metal-mecânico no estado do rio de janeiro

The main objective of this dissertation is to examine the implications of technological capacities in the improvement of technical performance indexes, specifically at the company level. These relationships were examined in a small sample of metal-working enterprises in the state of Rio de Janeiro (1960 to 2006). Although diverse studies on technological competences have been carried out in the last twenty years, a gap in empirical studies still exist that correlate the performance of companies in the context of developing countries, especially in Brazil. Aiming to contribute to a reduction of these gaps, this dissertation examines the questions by the light of available models in literature, which opting themselves to using operational indexes of companies. For drawing the accumulation of technological competences in this study, the metric proposal by Figueiredo (2000) shall be used indicating the levels of technological qualification in process, product, and equipment functions. The empirical evidence examined in this dissertation is both qualitative and quantitative in nature and were collected, first hand, through extensive field research involving informal interviews, meetings, direct-site observation and document analysis. In relation to the results, the evidence suggests that: - In terms of technological accumulation, a company reached Level 5 of technological capacity in process and organization of production as well as product and equipment. Three companies obtained Level 4 in the function process function while two others had reached the same technological level in the functions of product and equipment. Two companies had reached Level 3 in the product and equipment functions and one remained this level in the function of process; - In terms of the rate of accumulation of technological capacities, the observed companies had reached Level 4 needs 29 years in process function, 32 years in product function and 29 years in equipment function; - In terms of improvement performance pointers, a company which reached Level 5 of technological capacity improved in 70% of its indicators of performance, while the company that had achieved Level 4 had raised its pointers 60% and the other companies had gotten improved in the order of 40%. It was evidenced that the majority of the pointers of the companies with higher levels of technological capacities had obtained better performance. This dissertation contributes to advancing the strategic management of companies in metal-working segment to understanding internal accumulation of technological capacity and indicators of performance especially in the field of empirical context studied. This information offers management examples of how to improve competitive performance through the accumulation of technological capacities in the process, product and equipment functions.

Simulação computacional de medidas estereológicas em estruturas de metal duro (WC-Co)

This work focuses on the creation and applications of a dynamic simulation software in order to study the hard metal structure (WC-Co). The technological ground used to increase the GPU hardware capacity was Geforce 9600 GT along with the PhysX chip created to make games more realistic. The software simulates the three-dimensional carbide structure to the shape of a cubic box where tungsten carbide (WC) are modeled as triangular prisms and truncated triangular prisms. The program was proven effective regarding checking testes, ranging from calculations of parameter measures such as the capacity to increase the number of particles simulated dynamically. It was possible to make an investigation of both the mean parameters and distributions stereological parameters used to characterize the carbide structure through cutting plans. Grounded on the cutting plans concerning the analyzed structures, we have investigated the linear intercepts, the intercepts to the area, and the perimeter section of the intercepted grains as well as the binder phase to the structure by calculating the mean value and distribution of the free path. As literature shows almost consensually that the distribution of the linear intercepts is lognormal, this suggests that the grain distribution is also lognormal. Thus, a routine was developed regarding the program which made possible a more detailed research on this issue. We have observed that it is possible, under certain values for the parameters which define the shape and size of the Prismatic grain to find out the distribution to the linear intercepts that approach the lognormal shape. Regarding a number of developed simulations, we have observed that the distribution curves of the linear and area intercepts as well as the perimeter section are consistent with studies on static computer simulation to these parameters.

Estudo da molhabilidade de ligas de adição à base de prata sobre insertos cerâmicos para aplicação em brocas perfuração de poços de petróleo

Metal-ceramic interfaces are present in tricone drill bits with hard ceramic inserts for oil well drilling operations. The combination of actions of cutting, crushing and breaking up of rocks results in the degradation of tricone drill bits by wear, total or partial rupture of the drill bit body or the ceramic inserts, thermal shock and corrosion. Also the improper pressfitting of the ceramic inserts on the bit body may cause its total detachment, and promote serious damages to the drill bit. The improvement on the production process of metal-ceramic interfaces can eliminate or minimize some of above-mentioned failures presented in tricone drill bits, optimizing their lifetime and so reducing drilling metric cost. Brazing is a widely established technique to join metal-ceramic materials, and may be an excellent alternative to the common mechanical press fitting process of hard ceramic inserts on the steel bit body for tricone drill bit. Wetting phenomena plays an essential role in the production of metal/ceramic interfaces when a liquid phase is present in the process. In this work, 72Silver-28Copper eutectic based brazing alloys were melted onto zirconia, silicon nitride and tungsten carbide/Co substrates under high vacuum. Contact angle evolution was measured and graphically plotted, and the interfaces produced were analysed by SEM-EDX. The AgCu eutectic alloy did not wet any ceramic substrates, showing high contact angles, and so without chemical interaction between the materials. Better results were found for the systemns containing 3%wt of titanium in the AgCu alloy. The presence os titanium as a solute in the alloy produces wettable cand termodinamically stable compounds, increasing the ceramics wetting beahviour

Development of a new analytical approach based on cellulose membrane and chelator for differentiation of labile and inert metal species in aquatic systems

A new procedure was developed in this study, based on a system equipped with a cellulose membrane and a tetraethylenepentamine hexaacetate chelator (MD-TEPHA) for in situ characterization of the lability of metal species in aquatic systems. To this end, the DM-TEPHA system was prepared by adding TEPHA chelator to cellulose bags pre-purified with 1.0 mol L-1 of HCl and NaOH solutions. After the MD-TEPHA system was sealed, it was examined in the laboratory to evaluate the influence of complexation time (0-24 h), pH (3.0, 4.0, 5.0, 6.0 and 7.0), metal ions (Cu, Cd, Fe, Mn and Ni) and concentration of organic matter (15, 30 and 60 mg L-1) on the relative lability of metal species by TEPHA chelator. The results showed that Fe and Cu metals were complexed more slowly by TEPHA chelator in the MD-TEPHA system than were Cd, Ni and Mn in all pH used. It was also found that the pH strongly influences the process of metal complexation by the MD-TEPHA system. At all the pH levels, Cd, Mn and Ni showed greater complexation with TEPHA chelator (recovery of about 95-75%) than did Cu and Fe metals. Time also affects the lability of metal species complexed by aquatic humic substances (AHS); while Cd, Ni and Mn showed a faster kinetics, reaching equilibrium after about 100 min, and Cu and Fe approached equilibrium after 400 min. Increasing the AHS concentration decreases the lability of metal species by shifting the equilibrium to AHS-metal complexes. Our results indicate that the system under study offers an interesting alternative that can be applied to in situ experiments for differentiation of labile and inert metal species in aquatic systems. (c) 2006 Elsevier B.V. All rights reserved.

Activity of sesame leaf extracts to the leaf-cutting ant Atta sexdens rubropilosa (Hymenoptera : Formicidae)

Crude extracts of new and old sesame leaves (Sesamum indicum, Linaeus) obtained by a sequential process of extraction were tested through contact experiments to investigate their toxicity to Atta sexdens rubropilosa (Forel) workers. Methanol extract of old leaves was toxic to leaf-cutting ants at the lower tested concentration (20mg.ml(-1)). This extract was fractioned and their fractions were tested showing a toxic effect of the methanol fraction. The methanol fraction was fractioned again and the sub fraction responsible for worker's toxicity is composed of some sugars.

The influence of the scout upon the decision-making process of recruited workers in three Acromyrmex species (Formicidae : Attini)

We examined how the information communicated by a scout worker influences the plant species transported by recruited workers in Acromymex balzani, Acromyrmex rugosus, and Acromyrmex crassispinus, three species of leaf-cutting ant that have different substrate and habitat preferences. We verified that certain plant species were more likely to be transported than others and that recruitment occurs. We found that recruited workers were more likely to transport non-preferred plant species when they were recruited to these by scout workers. The results suggest that the scout worker can communicate information about plant identity to recruited workers, but that recruited workers integrate the information communicated with their own experience during the decision-making process. (C) 2004 Published by Elsevier B.V.

Utilização do éster de soja como biolubrificante

The lubricants found in the market are of mineral or synthetic origin and harm to humans and the environment, mainly due to their improper discard. Therefore industries are seeking to develop products that cause less environmental impact, so to decrease mainly, operator aggression the Cutting Fluids became an emulsion of oil / water or water / oil. However, the emulsion was not considered the most suitable solution for environmental question, therefore the search for biodegradable lubricants and which no are toxic continues and so vegetable oils are seen, again, as a basis for the production of lubricants. The biggest problem with these oils is their oxidative instability that is intensified when working at high temperatures. The process transesterification decreases the oxidation, however changes some physical and chemical properties. Therefore soybean oil after the transesterification process was subjected to tests of density, dynamic viscosity, kinematic viscosity which is calculated from two parameters mentioned, flash point and acidity. Besides the physico-chemical test the soybean oil was subjected to a dynamic test in a tribometer adapted from a table vise, whose induced wear was the adhesive and ultimately was used as cutting fluid in a process of turning in two different materials, steel 1045 and cast iron. This latter test presented results below the mineral cutting fluid which it was compared in all tests, already in other experiments the result was satisfactory and other experiments not, so that chemical additives can be added to the oil analyzed to try equate all parameters and so formulate a biolubrificante not toxic to apply in machining processes of metalworking industry

Pyrolysis and auto-gasification of black liquor in presence of ZnO: An integrated process for Zn/ZnO nanostructure production and bioenergy generation

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

Ultrathin films of lignins as a potential transducer in sensing applications involving heavy metal ions

Lignins extracted from sugar cane bagasse using different alcohols in the organosolv-CO(2) supercritical pulping process have been applied in the fabrication of ultrathin films through the Langmuir-Blodgett technique. Langmuir films were characterized by surface pressure versus mean molecular area (Pi-A) isotherms to exploit the sensitivity of nanostructured lignin films to metallic ions (Cu(2+), Cd(2+) and Pb(2+)). The Pi-A isotherms were shifted to larger molecular areas when heavy metal ions are present into the subphase, which might be related to electrostatic repulsions between metallic ions entrapped within the lignin molecular structure. Taking the advantage of metal incorporation, Langmuir monolayers were transferred onto solid substrates forming Langmuir-Blodgett (LB) films to be used as a transducer in an "electronic tongue" system to detect Cu(2+) in aqueous solution below threshold standard established by the Brazilian regulation. Both techniques impedance spectroscopy and electrochemistry have been used in these experiments. Complementary, Fourier transform infrared (FTIR) spectroscopy recorded for LB films before and after soaking into Cu(2+) aqueous solution revealed an interaction between the lignin phenyl groups and the metallic ion. (C) 2007 Elsevier B.V.. All rights reserved.

An Intelligent System for Petroleum Well Drilling Cutting Analysis

Cutting analysis is a important and crucial task task to detect and prevent problems during the petroleum well drilling process. Several studies have been developed for drilling inspection, but none of them takes care about analysing the generated cutting at the vibrating shale shakers. Here we proposed a system to analyse the cutting's concentration at the vibrating shale shakers, which can indicate problems during the petroleum well drilling process, such that the collapse of the well borehole walls. Cutting's images are acquired and sent to the data analysis module, which has as the main goal to extract features and to classify frames according to one of three previously classes of cutting's volume. A collection of supervised classifiers were applied in order to allow comparisons about their accuracy and efficiency. We used the Optimum-Path Forest (OPF), Artificial Neural Network using Multi layer Perceptrons (ANN-MLP), Support Vector Machines (SVM) and a Bayesian Classifier (BC) for this task. The first one outperformed all the remaining classifiers. Recall that we are also the first to introduce the OPF classifier in this field of knowledge. Very good results show the robustness of the proposed system, which can be also integrated with other commonly system (Mud-Logging) in order to improve the last one's efficiency.

Impedance of carrier injection at the metal-organic interface mediated by surface states in electron-only tris(8-hydroxyquinoline) aluminium (Alq(3)) thin layers

Capacitance spectra of thin (< 200 nm) Alq(3) electron-only devices have been measured as a function of bias voltage. Capacitance spectra exhibit a flat response at high frequencies (> 10(3) Hz) and no feature related to the carrier transit time is observed. Toward low frequencies the spectra reach a maximum and develop a negative excess capacitance. Capacitance response along with current-voltage (J-V) characteristics are interpreted in terms of the injection of electrons mediated by surface states at the metal organic interface. A detailed model for the impedance of the injection process is provided that highlights the role of the filling/releasing kinetics of energetically distributed interface states. This approach connects the whole capacitance spectra to the occupancy of interface states, with no additional information about bulk trap levels. Simulations based on the model allow to derive the density of interface states effectively intervening in the carrier injection (similar to 1.5 x 10(12) cm (2)). (C) 2008 Elsevier B.V. All rights reserved.

Analysis of the different forms of application and types of cutting fluid used in plunge cylindrical grinding using conventional and superabrasive CBN grinding wheels

The work reported here involved an investigation into the grinding process, one of the last finishing processes carried out on a production line. Although several input parameters are involved in this process, attention today focuses strongly on the form and amount of cutting fluid employed, since these substances may be seriously pernicious to human health and to the environment, and involve high purchasing and maintenance costs when utilized and stored incorrectly. The type and amount of cutting fluid used directly affect some of the main output variables of the grinding process which are analyzed here, such as tangential cutting force, specific grinding energy, acoustic emission, diametrical wear, roughness, residual stress and scanning electron microscopy. To analyze the influence of these variables, an optimised fluid application methodology was developed (involving rounded 5, 4 and 3 turn diameter nozzles and high fluid application pressures) to reduce the amount of fluid used in the grinding process and improve its performance in comparison with the conventional fluid application method (of diffuser nozzles and lower fluid application pressure). To this end, two types of cutting fluid (a 5% synthetic emulsion and neat oil) and two abrasive tools (an aluminium oxide and a superabrasive CBN grinding wheel) were used. The results revealed that, in every situation, the optimised application of cutting fluid significantly improved the efficiency of the process, particularly the combined use of neat oil and CBN grinding wheel. (c) 2005 Elsevier Ltd. All rights reserved.