Influence of optimized lubrication-cooling and minimum quantity lubrication on the cutting forces, on the geometric quality of the surfaces and on the micro-structural integrity of hardened steel parts

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

The usable leftover one-dimensional cutting stock problem-a priority-in-use heuristic

We consider a one-dimensional cutting stock problem in which the material not used in the cutting patterns, if large enough, is kept for use in the future. Moreover, it is assumed that leftovers should not remain in stock for a long time, hence, such leftovers have priority-in-use compared to standard objects (objects bought by the industry) in stock. A heuristic procedure is proposed for this problem, and its performance is analyzed by solving randomly generated dynamic instances where successive problems are solved in a time horizon. For each period, new demands arise and a new problem is solved on the basis of the information about the stock of the previous periods (remaining standard objects in the stock) and usable leftovers generated during those previous periods. The computational experiments show that the solutions presented by the proposed heuristic are better than the solutions obtained by other heuristics from the literature. © 2012 The Authors. International Transactions in Operational Research © 2012 International Federation of Operational Research Societies.

Growth Control of Microbial in Miscible Cutting Fluids Using Ultraviolet Radiation

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

Effects of rock properties on specific cutting energy in linear cutting of sandstones by picks

Specific cutting energy (SE) has been widely used to assess the rock cuttability for mechanical excavation purposes. Some prediction models were developed for SE through correlating rock properties with SE values. However, some of the textural and compositional rock parameters i.e. texture coefficient and feldspar, mafic, and felsic mineral contents were not considered. The present study is to investigate the effects of previously ignored rock parameters along with engineering rock properties on SE. Mineralogical and petrographic analyses, rock mechanics, and linear rock cutting tests were performed on sandstone samples taken from sites around Ankara, Turkey. Relationships between SE and rock properties were evaluated using bivariate correlation and linear regression analyses. The tests and subsequent analyses revealed that the texture coefficient and feldspar content of sandstones affected rock cuttability, evidenced by significant correlations between these parameters and SE at a 90% confidence level. Felsic and mafic mineral contents of sandstones did not exhibit any statistically significant correlation against SE. Cementation coefficient, effective porosity, and pore volume had good correlations against SE. Poisson's ratio, Brazilian tensile strength, Shore scleroscope hardness, Schmidt hammer hardness, dry density, and point load strength index showed very strong linear correlations against SE at confidence levels of 95% and above, all of which were also found suitable to be used in predicting SE individually, depending on the results of regression analysis, ANOVA, Student's t-tests, and R-2 values. Poisson's ratio exhibited the highest correlation with SE and seemed to be the most reliable SE prediction tool in sandstones.

Evaluation of the indirect measures of rock brittleness and fracture toughness in rock cutting

Performance prediction models for partial face mechanical excavators, when developed in laboratory conditions, depend on relating the results of a set of rock property tests and indices to specific cutting energy (SE) for various rock types. There exist some studies in the literature aiming to correlate the geotechnical properties of intact rocks with the SE, especially for massive and widely jointed rock environments. However, those including direct and/or indirect measures of rock fracture parameters such as rock brittleness and fracture toughness, along with the other rock parameters expressing different aspects of rock behavior under drag tools (picks), are rather limited. With this study, it was aimed to investigate the relationships between the indirect measures of rock brittleness and fracture toughness and the SE depending on the results of a new and two previous linear rock cutting programmes. Relationships between the SE, rock strength parameters, and the rock index tests have also been investigated in this study. Sandstone samples taken from the different fields around Ankara, Turkey were used in the new testing programme. Detailed mineralogical analyses, petrographic studies, and rock mechanics and rock cutting tests were performed on these selected sandstone specimens. The assessment of rock cuttability was based on the SE. Three different brittleness indices (B1, B2, and B4) were calculated for sandstones samples, whereas a toughness index (T-i), being developed by Atkinson et al.(1), was employed to represent the indirect rock fracture toughness. The relationships between the SE and the large amounts of new data obtained from the mineralogical analyses, petrographic studies, rock mechanics, and linear rock cutting tests were evaluated by using bivariate correlation and curve fitting techniques, variance analysis, and Student's t-test. Rock cutting and rock property testing data that came from well-known studies of McFeat-Smith and Fowell(2) and Roxborough and Philips(3) have also been employed in statistical analyses together with the new data. Laboratory tests and subsequent analyses revealed that there were close correlations between the SE and B4 whereas no statistically significant correlation has been found between the SE and T-i. Uniaxial compressive and Brazilian tensile strengths and Shore scleroscope hardness of sandstones also exhibited strong relationships with the SE. NCB cone indenter test had the greatest influence on the SE among the other engineering properties of rocks, confirming the previous studies in rock cutting and mechanical excavation. Therefore, it was recommended to employ easy-to-use index tests of NCB cone indenter and Shore scleroscope in the estimation of laboratory SE of sandstones ranging from very low to high strengths in the absence of a rock cutting rig to measure it until the easy-to-use universal measures of the rock brittleness and especially the rock fracture toughness, being an intrinsic rock property, are developed.

The influence of tool geometry on the performance of drilling tools

The main objective of the work presented in this thesis is to investigate the two sides of the flute, the face and the heel of a twist drill. The flute face was designed to yield straight diametral lips which could be extended to eliminate the chisel edge, and consequently a single cutting edge will be obtained. Since drill rigidity and space for chip conveyance have to be a compromise a theoretical expression is deduced which enables optimum chip disposal capacity to be described in terms of drill parameters. This expression is used to describe the flute heel side. Another main objective is to study the effect on drill performance of changing the conventional drill flute. Drills were manufactured according to the new flute design. Tests were run in order to compare the performance of a conventional flute drill and non conventional design put forward. The results showed that 50% reduction in thrust force and approximately 18% reduction in torque were attained for the new design. The flank wear was measured at the outer corner and found to be less for the new design drill than for the conventional one in the majority of cases. Hole quality, roundness, size and roughness were also considered as a further aspect of drill performance. Improvement in hole quality is shown to arise under certain cutting conditions. Accordingly it might be possible to use a hole which is produced in one pass of the new drill which previously would have required a drilled and reamed hole. A subsidiary objective is to design the form milling cutter that should be employed for milling the foregoing special flute from drill blank allowing for the interference effect. A mathematical analysis in conjunction with computing technique and computers is used. To control the grinding parameter, a prototype drill grinder was designed and built upon the framework of an existing cincinnati cutter grinder. The design and build of the new grinder is based on a computer aided drill point geometry analysis. In addition to the conical grinding concept, the new grinder is also used to produce spherical point utilizing a computer aided drill point geometry analysis.

Some aspects of drill performance

High speed twist drills are probably the most common of all metal cutting tools and also the least efficient. In this study, detailed research was undertaken into aspects of drill performance and ways in which drilling could be improved in short hole depths of up to two diameters. The work included an evaluation of twist drill geometry and grinding parameters. It was established that errors in point grinding lead to increased hole oversize and reduced drill life. A fundamental analysis was made to establish predictive equations for the drill torque and thrust using modified orthogonal cutting equations and empirical data. A good correlation was obtained between actual and predicted results. Two new techniques for extending twist drill life by the use of coolant feeding holes and also the application of titanium nitride coatings were evaluated. Both methods were found to have potential for improving drill performance. A completely new design of carbide tipped drill was designed and developed. The new design was tested and it compared favourably with two commercially available carbide tipped drills. In further work an entirely different type of drill point geometry was developed for the drill screw. A new design was produced which enabled the drilling time to be minimised for the low thrust forces that were likely to be used with hand held power tools.

The influence of cutting tool geometry upon aspects of chip flow and tool wear:a theoretical, three dimensional examination of the cutting geometry and the shape of the twist drill

This work is undertaken in the attempt to understand the processes at work at the cutting edge of the twist drill. Extensive drill life testing performed by the University has reinforced a survey of previously published information. This work demonstrated that there are two specific aspects of drilling which have not previously been explained comprehensively. The first concerns the interrelating of process data between differing drilling situations, There is no method currently available which allows the cutting geometry of drilling to be defined numerically so that such comparisons, where made, are purely subjective. Section one examines this problem by taking as an example a 4.5mm drill suitable for use with aluminium. This drill is examined using a prototype solid modelling program to explore how the required numerical information may be generated. The second aspect is the analysis of drill stiffness. What aspects of drill stiffness provide the very great difference in performance between short flute length, medium flute length and long flute length drills? These differences exist between drills of identical point geometry and the practical superiority of short drills has been known to shop floor drilling operatives since drilling was first introduced. This problem has been dismissed repeatedly as over complicated but section two provides a first approximation and shows that at least for smaller drills of 4. 5mm the effects are highly significant. Once the cutting action of the twist drill is defined geometrically there is a huge body of machinability data that becomes applicable to the drilling process. Work remains to interpret the very high inclination angles of the drill cutting process in terms of cutting forces and tool wear but aspects of drill design may already be looked at in new ways with the prospect of a more analytical approach rather than the present mix of experience and trial and error. Other problems are specific to the twist drill, such as the behaviour of the chips in the flute. It is now possible to predict the initial direction of chip flow leaving the drill cutting edge. For the future the parameters of further chip behaviour may also be explored within this geometric model.

Integrated optimisation of surface roughness and tool performance when face milling 416 SS

Tool life is an important factor to be considered during the optimisation of a machining process since cutting parameters can be adjusted to optimise tool changing, reducing cost and time of production. Also the performance of a tool is directly linked to the generated surface roughness and this is important in cases where there are strict surface quality requirements. The prediction of tool life and the resulting surface roughness in milling operations has attracted considerable research efforts. The research reported herein is focused on defining the influence of milling cutting parameters such as cutting speed, feed rate and axial depth of cut, on three major tool performance parameters namely, tool life, material removal and surface roughness. The research is seeking to define methods that will allow the selection of optimal parameters for best tool performance when face milling 416 stainless steel bars. For this study the Taguchi method was applied in a special design of an orthogonal array that allows studying the entire parameter space with only a number of experiments representing savings in cost and time of experiments. The findings were that the cutting speed has the most influence on tool life and surface roughness and very limited influence on material removal. By last tool life can be judged either from tool life or volume of material removal.

Tool cutting force modeling and wear estimation of micro -end-milling operations

The applications of micro-end-milling operations have increased recently. A Micro-End-Milling Operation Guide and Research Tool (MOGART) package has been developed for the study and monitoring of micro-end-milling operations. It includes an analytical cutting force model, neural network based data mapping and forecasting processes, and genetic algorithms based optimization routines. MOGART uses neural networks to estimate tool machinability and forecast tool wear from the experimental cutting force data, and genetic algorithms with the analytical model to monitor tool wear, breakage, run-out, cutting conditions from the cutting force profiles. ^ The performance of MOGART has been tested on the experimental data of over 800 experimental cases and very good agreement has been observed between the theoretical and experimental results. The MOGART package has been applied to the micro-end-milling operation study of Engineering Prototype Center of Radio Technology Division of Motorola Inc. ^

Tool cutting force modeling and wear estimation of micro-end-milling operations

The applications of micro-end-milling operations have increased recently. A Micro-End-Milling Operation Guide and Research Tool (MOGART) package has been developed for the study and monitoring of micro-end-milling operations. It includes an analytical cutting force model, neural network based data mapping and forecasting processes, and genetic algorithms based optimization routines. MOGART uses neural networks to estimate tool machinability and forecast tool wear from the experimental cutting force data, and genetic algorithms with the analytical model to monitor tool wear, breakage, run-out, cutting conditions from the cutting force profiles. The performance of MOGART has been tested on the experimental data of over 800 experimental cases and very good agreement has been observed between the theoretical and experimental results. The MOGART package has been applied to the micro-end-milling operation study of Engineering Prototype Center of Radio Technology Division of Motorola Inc.

Effets des procédés d’usinage de finition sur les propriétés de surface, la performance d’un vernis et l’émission de poussières du bois de chêne rouge

La performance d’un produit de finition sur le bois est influencée par la manière dont la surface est préparée. Le ponçage est très utilisé pour préparer les surfaces lors de la finition. Toutefois, ce procédé génère une grande quantité de poussières. Ainsi, les effets des procédés d’usinage sur les propriétés de surface, la performance d’un vernis et l’émission de poussières ont été étudiés dans le but de déterminer les modes de préparation des surfaces les plus adéquats pour le bois de chêne rouge. Dans un premier volet, les propriétés de surface et la performance d’un vernis ont été évaluées sur les surfaces préparées à l’aide du procédé traditionnel de ponçage et de trois procédés alternatifs de rabotage soit la coupe périphérique droite, la coupe hélicoïdale et la coupe oblique. La qualité de surface a été évaluée au moyen des caractéristiques de rugosité, d’endommagement cellulaire et de mouillabilité. Des essais de résistance à l’adhésion d’un vernis d’usage intérieur ont été effectués avant et après un traitement de vieillissement accéléré. Les résultats ont montré que le ponçage a induit une rugosité et un niveau de fibrillation supérieurs à ceux des autres procédés, ainsi qu’une mouillabilité et une adhésion du vernis après vieillissement accéléré élevées. Les surfaces rabotées avec la coupe périphérique droite ont présenté un certain niveau de fibrillation, une rugosité et une mouillabilité intermédiaires. Néanmoins, l’adhésion du vernis après vieillissement a été également inférieure par rapport aux autres procédés. La coupe hélicoïdale a produit une rugosité intermédiaire. D’autre part, la coupe oblique a été le procédé qui a présenté une perte d’adhésion après vieillissement similaire au ponçage. Ce procédé a généré des surfaces lisses avec rugosité et mouillabilité intermédiaires. Sur la base des résultats obtenus, le ponçage à l’aide d’un programme P100-grain et une vitesse d’avance de 7 m/min, la coupe périphérique droite avec un angle d’attaque de 25° et une onde d’usinage de 1,0 mm, la coupe hélicoïdale avec une onde d’usinage de 1,0 mm et la coupe oblique realisé avec un angle oblique de 15° ont permis d’obtenir les meilleures conditions d’usinage pour chaque procédé. Dans un deuxième volet, l’effet de différents paramètres de coupe sur l’émission de poussières et la rugosité de la surface a été étudié lors de la coupe hélicoïdale. Les émissions de poussières ont diminué avec la diminution de laprofondeur de coupe et l’augmentation de l’épaisseur moyenne du copeau. Cependant, les surfaces obtenues avec l’épaisseur moyenne du copeau plus élevée ont présenté une rugosité supérieure. Par contre, si une surface plus lisse est requise, une vitesse d’avance intermédiaire doit être utilisée afin de diminuer la rugosité des surfaces sans exposer les travailleurs à des niveaux élevés de poussière de bois. Par ailleurs, l’émission de poussières pour chaque fraction de particules peut être estimée à travers les modèles développés.

Influence of the cutting edge micro-geometry of PCBN tools on the flank wear in orthogonal quenched and tempered turning M2 steel

Quenched and tempered high-speed steels obtained by powder metallurgy are commonly used in automotive components, such as valve seats of combustion engines. In order to machine these components, tools with high wear resistance and appropriate cutting edge geometry are required. This work aims to investigate the influence of the edge preparation of polycrystalline cubic boron nitride (PCBN) tools on the wear behavior in the orthogonal longitudinal turning of quenched and tempered M2 high-speed steels obtained by powder metallurgy. For this research, PCBN tools with high and low-CBN content have been used. Two different cutting edge geometries with a honed radius were tested: with a ground land (S shape) and without it (E shape). Also, the cutting speed was varied from 100 to 220 m/min. A rigid CNC lathe was used. The results showed that the high-CBN, E-shaped tool presented the longest life for a cutting speed of 100 m/min. High-CBN tools with a ground land and honed edge radius (S shaped) showed edge damage and lower values of the tool’s life. Low-CBN, S-shaped tools showed similar results, but with an inferior performance when compared with tools with high CBN content in both forms of edge preparation.

Comparison of sequence variants in the PDK4 and COX4I2 genes between racing and cutting lines of quarter horses and associations with the speed index.

Different selection objectives within the Quarter Horse breed led to the formation of groups with distinct skills, including the racing and cutting lines. With a smaller population size in Brazil, but of great economic representativeness, the racing line is characterized by animals that can reach high speeds over short distances and within a short period of time. The cutting line is destined for functional tests, exploring skills such as agility and obedience. Although the athletic performance of horses is likely to be influenced by a large number of genes, few genetic variants have so far been related to this trait and this was done exclusively in Thoroughbreds, including the g.38973231G>A singlenucleotide polymorphism in the PDK4 gene and the g.22684390C>T single-nucleotide polymorphism in the COX4I2 gene. The results of the present study demonstrate the presence of polymorphic PDK4 and COX4I2 genes in Quarter Horses. The analysis of 296 racing animals and 68 cutting animals revealed significant differences in allele and genotype frequencies between the two lines. The same was not observed when these frequencies were compared between extreme racing performance phenotypes. There were also no significant associations between alleles of the two polymorphisms and the speed index. These results suggest that the alleles of the PDK4 and COX4I2 genes, which are related to better racecourse performance in Thoroughbreds, are probably associated with beneficial adaptations in aerobic metabolism and therefore play secondary roles in sprint racing performance in Quarter Horses, which is mainly anaerobic.