Influência na qualidade final de metais retificados através da variação da velocidade de mergulho

A retificação, processo final de usinagem de uma peça, utiliza fluidos de corte com a finalidade de lubrificação, refrigeração e remoção de cavacos. No entanto, esses fluidos são extremamente agressivos com o meio. Com o avanço tecnológico a tendência mundial é produzir peças cada vez mais sofisticadas, com elevado grau de tolerância geométrica, dimensional, com bom acabamento superficial, com baixo custo e, principalmente, sem causar danos ao meio. Para tanto, ao processo de retificação está intrínseca a reciclagem do fluido de corte, que se destaca pelo seu custo. Através da variação da velocidade de avanço no processo de retificação cilíndrica externa do aço ABNT D6, racionalizando a aplicação de dois fluidos de corte e usando um rebolo superabrasivo de CBN (nitreto de boro cúbico) com ligante vitrificado, avaliaram-se os parâmetros de saída da força tangencial de corte, emissão acústica, rugosidade, circularidade, desgaste da ferramenta, tensão residual e a integridade superficial através da microscopia eletrônica de varredura (MEV) dos corpos-de-prova. Com a análise do desempenho do fluido, do rebolo e da velocidade de mergulho, encontraram-se as melhores condições de usinagem propiciando a diminuição do volume de fluido de corte e a diminuição do tempo de usinagem, sem prejudicar os parâmetros geométricos e dimensionais, o acabamento superficial e a integridade superficial dos componentes.

Appraisal of open software for finite element simulation of 2D metal sheet laser cut.

FEA simulation of thermal metal cutting is central to interactive design and manufacturing. It is therefore relevant to assess the applicability of FEA open software to simulate 2D heat transfer in metal sheet laser cuts. Application of open source code (e.g. FreeFem++, FEniCS, MOOSE) makes possible additional scenarios (e.g. parallel, CUDA, etc.), with lower costs. However, a precise assessment is required on the scenarios in which open software can be a sound alternative to a commercial one. This article contributes in this regard, by presenting a comparison of the aforementioned freeware FEM software for the simulation of heat transfer in thin (i.e. 2D) sheets, subject to a gliding laser point source. We use the commercial ABAQUS software as the reference to compare such open software. A convective linear thin sheet heat transfer model, with and without material removal is used. This article does not intend a full design of computer experiments. Our partial assessment shows that the thin sheet approximation turns to be adequate in terms of the relative error for linear alumina sheets. Under mesh resolutions better than 10e−5 m , the open and reference software temperature differ in at most 1 % of the temperature prediction. Ongoing work includes adaptive re-meshing, nonlinearities, sheet stress analysis and Mach (also called ‘relativistic’) effects.

EGCL: an extended G-Code Language with flow control, functions and mnemonic variables

In the context of computer numerical control (CNC) and computer aided manufacturing (CAM), the capabilities of programming languages such as symbolic and intuitive programming, program portability and geometrical portfolio have special importance -- They allow to save time and to avoid errors during part programming and permit code re-usage -- Our updated literature review indicates that the current state of art presents voids in parametric programming, program portability and programming flexibility -- In response to this situation, this article presents a compiler implementation for EGCL (Extended G-code Language), a new, enriched CNC programming language which allows the use of descriptive variable names, geometrical functions and flow-control statements (if-then-else, while) -- Our compiler produces low-level generic, elementary ISO-compliant Gcode, thus allowing for flexibility in the choice of the executing CNC machine and in portability -- Our results show that readable variable names and flow control statements allow a simplified and intuitive part programming and permit re-usage of the programs -- Future work includes allowing the programmer to define own functions in terms of EGCL, in contrast to the current status of having them as library built-in functions

Spectral-based mesh segmentation

In design and manufacturing, mesh segmentation is required for FACE construction in boundary representation (BRep), which in turn is central for featurebased design, machining, parametric CAD and reverse engineering, among others -- Although mesh segmentation is dictated by geometry and topology, this article focuses on the topological aspect (graph spectrum), as we consider that this tool has not been fully exploited -- We preprocess the mesh to obtain a edgelength homogeneous triangle set and its Graph Laplacian is calculated -- We then produce a monotonically increasing permutation of the Fiedler vector (2nd eigenvector of Graph Laplacian) for encoding the connectivity among part feature submeshes -- Within the mutated vector, discontinuities larger than a threshold (interactively set by a human) determine the partition of the original mesh -- We present tests of our method on large complex meshes, which show results which mostly adjust to BRep FACE partition -- The achieved segmentations properly locate most manufacturing features, although it requires human interaction to avoid over segmentation -- Future work includes an iterative application of this algorithm to progressively sever features of the mesh left from previous submesh removals

Estudo da sinterização de cavacos de aço ferritico

This research studies the sintering of ferritic steel chips from the machining process. Were sintered metal powder obtained from machining process chips for face milling of a ferritic steel. The chip was produced by machining and characterized by SEM and EDS, and underwent a process of high energy mill powder characterized also by SEM and EDS. Were constructed three types of matrixes for uniaxial compression (relation l / d greater than 2.5). The differences in the design of the matrixes were essentially in the direction of load application, which for cylindrical case axial direction, while for the rectangular arrays, the longer side. Two samples were compressed with different geometries, a cylindrical and rectangular with the same compaction pressure of 700 MPa. The samples were sintered in a vacuum resistive furnace, heating rate 20 °C / min., isotherm 1300 °C for 60 minutes, and cooling rate of 25 °C / min to room temperature. The starting material of the rectangular sample was further annealed up to temperature of 800 ° C for 30 min. Sintered samples were characterized by scanning electron microscopy, optical microscopy and EDS. The sample compressed in the cylindrical matrix did not show a regular density reflecting in the sintered microstructure revealed by the irregular geometry of the pores, characterizing that the sintering was not complete, reaching only the second phase. As for the specimen compacted in the rectangular array, the analysis performed by scanning electron microscopy, optical microscopy and EDS indicate a good densification, and homogeneous microstructure in their full extent. Additionally, the EDS analyzes indicate no significant changes in chemical composition in the process steps. Therefore, it is concluded that recycling of chips, from the processed ferritic steel is feasible by the powder metallurgy. It makes possible rationalize raw material and energy by manufacture of known properties components from chips generated by the machining process, being benefits to the environment

Chatter avoidance in the milling of thin floors with bull-nose end mills: Model and stability diagrams

The milling of thin parts is a high added value operation where the machinist has to face the chatter problem. The study of the stability of these operations is a complex task due to the changing modal parameters as the part loses mass during the machining and the complex shape of the tools that are used. The present work proposes a methodology for chatter avoidance in the milling of flexible thin floors with a bull-nose end mill. First, a stability model for the milling of compliant systems in the tool axis direction with bull-nose end mills is presented. The contribution is the averaging method used to be able to use a linear model to predict the stability of the operation. Then, the procedure for the calculation of stability diagrams for the milling of thin floors is presented. The method is based on the estimation of the modal parameters of the part and the corresponding stability lobes during the machining. As in thin floor milling the depth of cut is already defined by the floor thickness previous to milling, the use of stability diagrams that relate the tool position along the tool-path with the spindle speed is proposed. Hence, the sequence of spindle speeds that the tool must have during the milling can be selected. Finally, this methodology has been validated by means of experimental tests.

Microfabricated elastomer tactile sensors for robotic fingertip systems

Tactile sensing is an important aspect of robotic systems, and enables safe, dexterous robot-environment interaction. The design and implementation of tactile sensors on robots has been a topic of research over the past 30 years, and current challenges include mechanically flexible “sensing skins”, high dynamic range (DR) sensing (i.e.: high force range and fine force resolution), multi-axis sensing, and integration between the sensors and robot. This dissertation focuses on addressing some of these challenges through a novel manufacturing process that incorporates conductive and dielectric elastomers in a reusable, multilength-scale mold, and new sensor designs for multi-axis sensing that improve force range without sacrificing resolution. A single taxel was integrated into a 1 degree of freedom robotic gripper for closed-loop slip detection. Manufacturing involved casting a composite silicone rubber, polydimethylsiloxane (PDMS) filled with conductive particles such as carbon nanotubes, into a mold to produce microscale flexible features on the order of 10s of microns. Molds were produced via microfabrication of silicon wafers, but were limited in sensing area and were costly. An improved technique was developed that produced molds of acrylic using a computer numerical controlled (CNC) milling machine. This maintained the ability to produce microscale features, and increased the sensing area while reducing costs. New sensing skins had features as small as 20 microns over an area as large as a human hand. Sensor architectures capable of sensing both shear and normal force sensing with high dynamic range were produced. Using this architecture, two sensing modalities were developed: a capacitive approach and a contact resistive approach. The capacitive approach demonstrated better dynamic range, while the contact resistive approach used simpler circuitry. Using the contact resistive approach, normal force range and resolution were 8,000 mN and 1,000 mN, respectively, and shear force range and resolution were 450 mN and 100 mN, respectively. Using the capacitive approach, normal force range and resolution were 10,000 mN and 100 mN, respectively, and shear force range and resolution were 1,500 mN and 50 mN, respectively.

Estudo da viabilidade do processo de reciclagem do material descartado do sistema Zirkonzanh® de produção de próteses dentárias

At present, the material of choice for performing aesthetic dental prosthetic work is in the ceramic. Among them, the ceramic base of stabilized zirconia with 3% yttria (3Y - TZP) stand out for having excellent physical and mechanical properties. During the machining of blocks of zirconia in the laboratory to prepare the various types of prostheses, much of the material is given off in the form of powder, which is subsequently discarded. The waste of this material results in financial loss, reflecting higher final cost treatment for patients, as well as damage to the environment, thanks to the processes involved in the manufacture and disposal of the ceramic. This research, pioneered the recycling of zirconium oxide powder obtained during milling of dental crowns and bridges, we highlight the social and environmental aspects and aims to establish a protocol for the reuse of waste (powder of zirconia Zirkonzahn® system) discarded to obtain a new block of compacted zirconia to maintain the same mechanical and microstructural properties of commercial high-cost imported material. To compare with the commercial material, samples were uniaxially (20 MPa) and isostatically (100 MPa), and its mechanical and microstructural characterization was performed through tests of density, porosity, dilatometry, X-ray diffraction (XRD), hardness, fracture toughness, resistance to fracture electron microscopy (SEM) and analysis of grain size. The results observed in the samples were isostatically pressed similiares those obtained with samples from the commercial material demonstrating the viability of the process

Effects in ultrafast laser micromachining PMMA-based optical fibre grating

Ultrafast laser owns extreme small beam size and high pulse intensity which enable spatial localised modification either on the surface or in the bulk of materials. Therefore, ultrafast laser has been widely used to micromachine optical fibres to alter optical structures. In order to do the precise control of the micromachining process to achieve the desired structure and modification, investigations on laser parameters control should be carried out to make better understanding of the effects in the laser micromachining process. These responses are important to laser machining, most of which are usually unknown during the process. In this work, we report the real time monitored results of the reflection of PMMA based optical fibre Bragg gratings (POFBGs) during excimer ultraviolet laser micromachining process. Photochemical and thermal effects have been observed during the process. The UV radiation was absorbed by the PMMA material, which consequently induced the modifications in both spatial structure and material properties of the POFBG. The POFBG showed a significant wavelength blue shift during laser micromachining. Part of it attributed to UV absorption converted thermal energy whilst the other did not disappear after POFBG cooling off, which attributed to UV induced photodegradation in POF.

O efeito da aplicação do SNC no Capital Próprio em empresas do Setor Agrícola

O processo de Harmonização Contabilística é um processo que surge em consequência do processo de Globalização da Economia. Com a evolução do comércio global, exige-se que a informação contabilística seja mais uniforme entre os diversos países/continentes, para que os utilizadores dessa informação possam tomar as melhores decisões. Em Portugal, o referido processo tem sido influenciado pela regulamentação produzida a nível europeu. Fruto desta influência, a partir de 01 de janeiro de 2005 as empresas cotadas em bolsa ficaram obrigadas a aplicar as International Accounting Standards/International Financial Reporting Standards (IAS/IFRS) e as Standing Interpretations Committee/International Financial Reporting Interpretations Committee (SIC/IFRIC), de acordo com o Regulamento 1606/CE/2002. Em 2003, a CNC elaborou um projeto de linhas de orientação para um novo modelo de normalização contabilística, documento que serviria de base ao Projeto do novo Sistema de Normalização Contabilística (SNC), tendo o novo SNC entrado em vigor em 1 de janeiro de 2010. É, pois, dentro destas alterações introduzidas no normativo contabilístico nacional que se desenvolve este estudo, que tem como principal objetivo analisar e quantificar os impactos sobre o Capital Próprio, decorrentes da adoção do SNC em empresas do setor agrícola. Para o efeito utilizamos uma amostra de 6980 empresas do referido setor. Dos resultados obtidos concluímos que 4910 empresas, o que representa 70,34% do total, apresentaram alterações no Capital Próprio. A rubrica Reserva foi aquela que mais vezes sofreu variações, tendo sido alterada no Balanço de 4008 empresas. As alterações no Capital Próprio têm impacto nos rácios de Solvabilidade Financeira e Autonomia Financeira. Uma análise desses indicadores permitiu-nos concluir que, em termos de Solvabilidade Financeira, 6,32 % das empresas (441) pioraram a sua situação, 81,15 % (5664) mantiveram-na inalterada e 6,72 % (469) melhoraram a sua Solvabilidade Financeira. Relativamente à Autonomia Financeira as variações foram menos significativas, pois 99,07 % (6915 empresas) mantiveram inalterado o seu desempenho, 0,11 % (8 empresas) pioraram a sua situação relativamente ao presente indicador e 0,19 % (13 empresas) melhoraram. No entanto, estes indicadores de equilíbrio financeiro devem ser analisados num contexto de transição, uma vez que não se verificou um real aumento ou diminuição da estrutura de Capitais Próprios destas empresas, mas apenas uma nova reconfiguração contabilística.

Conception of a YBCO Superconducting ZFC-Magnetic Bearing Virtual Prototype

This paper presents the conception of an original superconducting Frictionless Zero Field Cooling bearing virtual prototype. In previous work also shown in this conference, a viability study of a Zero Field Cooling-superconducting bearing concept was conducted. It showed that the virtual prototype is feasible. Moreover, the simulation studies showed that a Zero Field Cooling superconducting track provides not only effective lateral stability but also higher levitation forces than the commonly used Field Cooling tracks. In this paper the new Zero Field Cooling -bearing virtual prototype is modeled in 3D. The virtual prototype was designed having in mind: i) a future implementation in high density polyurethane, for low temperature robustness; ii) future manufacturing in a three axes CNC milling machine and; iii) future implementation of some parts using an additive manufacturing technique.

Modelli variazionali convessi-nonconvessi per la ricostruzione di segnali bilivello corrotti da sfocamento e rumore: analisi e soluzione numerica.

In questa tesi abbiamo presentato/analizzato metodi variazionali allo stato dell’arte per la ricostruzione – ovvero, rimozione di sfocamento e rumore - di una classe specifica di segnali/immagini caratterizzati dal fatto di essere costanti a tratti e bilivello. Tali metodi ottengono la ricostruzione tramite la minimizzazione di un funzionale formato da due parti: un termine di fedeltà ai dati, la cui forma dipende dal tipo di rumore considerato, e un termine di regolarizzazione che codifica l’informazione a priori disponibile sul segnale da ricostruire (ad esempio, la sua regolarità). Per segnali costanti a tratti, è ben noto che il regolarizzatore deve avere la proprietà di promuovere la sparsità delle derivate prime del segnale. In particolare, molte proposte allo stato dell’arte sfruttano la pseudo-norma l0 o la norma l1 del gradiente, ossia la Variazione Totale (TV). La prima scelta è ottimale in linea teorica poiché promuove al meglio la sparsità, ma il funzionale è fortemente non convesso e i metodi numerici di minimizzazione possono convergere a soluzioni locali. Nel caso di TV si ha invece un problema convesso che garantisce la convergenza a minimi globali ma la qualità della soluzione è sub-ottima. Motivati da vantaggi/svantaggi di l0 ed l1, in questa tesi si è deciso di investigare (teoricamente e sperimentalmente) l’uso di modelli variazionali di tipo Convesso-NonConvesso (CNC). Questi utilizzano particolari regolarizzatori non convessi e parametrici che consentono da un lato di sparsificare meglio di l1, dall’altro di mantenere la convessità del funzionale così da presentare un unico punto di minimo. Tra i metodi CNC investigati, quello denominato GME-TV basato sul concetto di inviluppo di Moreau generalizzato ha prodotto ricostruzioni di qualità sempre migliore di TV e a volte, diremmo sorprendentemente, anche di l0. Questo rappresenta un risultato di particolare rilevanza scientifica nel campo della ricostruzione di segnali/immagini.