Stability lobes diagram identification and surface roughness monitoring in milling processes

La millora de la productivitat i la qualitat són indubtablement dues de les principals exigències del sector productiu modern i factors clau per la competitivitat i la supervivència. Dins aquest sector,la fabricació per arrancada de material juga encara avui en dia un paper protagonista tot i l'aparició de noves tècniques de conformat per addició.Indústries com l'aeronàutica, l'automobilística,la del motlle o l'energètica, depenen en bona part de les prestacions de les màquines-eina. Aquesta Tesi aborda dos aspectes rellevants quan es tracta de millorar de la productivitat i la qualitat del sector productiu: el problema del fimbrament, més conegut per la denominació anglosaxona chatter,i la monitorització de la rugositat superficial en el mecanitzat a alta velocitat.

Temperature-dependent orientational ordering on a spherical surface modeled with a lattice spin model

We study the orientational ordering on the surface of a sphere using Monte Carlo and Brownian dynamics simulations of rods interacting with an anisotropic potential. We restrict the orientations to the local tangent plane of the spherical surface and fix the position of each rod to be at a discrete point on the spherical surface. On the surface of a sphere, orientational ordering cannot be perfectly nematic due to the inevitable presence of defects. We find that the ground state of four +1/2 point defects is stable across a broad range of temperatures. We investigate the transition from disordered to ordered phase by decreasing the temperature and find a very smooth transition. We use fluctuations of the local directors to estimate the Frank elastic constant on the surface of a sphere and compare it to the planar case. We observe subdiffusive behavior in the mean square displacement of the defect cores and estimate their diffusion constants.

GREEN MACHINING ORIENTED TO DIMINISH DENSITY GRADIENT FOR MINIMIZATION of DISTORTION IN ADVANCED CERAMICS

After sintering advanced ceramics, there are invariably distortions, caused in large part by the heterogeneous distribution of density gradients along the compacted piece. To correct distortions, machining is generally used to manufacture pieces within dimensional and geometric tolerances. Hence, narrow material removal limit conditions are applied, which minimize the generation of damage. Another alternative is machining the compacted piece before sintering, called the green ceramic stage, which allows machining without damage to mechanical strength. Since the greatest concentration of density gradients is located in the outer-most layers of the compacted piece, this study investigated the removal of different allowance values by means of green machining. The output variables are distortion after sintering, tool wear, cutting force, and the surface roughness of the green ceramics and the sintered ones. The following results have been noted: less distortion is verified in the sintered piece after 1mm allowance removal; and the higher the tool wear the worse the surface roughness of both green and sintered pieces.

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.

Investigation on Surface Finishing of Components Ground with Lapping Kinematics: Lapgrinding Process

Over the last three decades, researchers have responded to the demands of industry to manufacture mechanical components with geometrical tolerance, dimensional tolerance, and surface finishing in nanometer levels. The new lapgrinding process developed in Brazil utilizes lapping kinematics and a flat grinding wheel dressed with a single-point diamond dresser in agreement with overlap factor (U(d)) theory. In the present work, the influences of different U(d) values on dressing (U(d) = 1, 3 e 5) and grain size of the grinding wheel made of silicon carbide (SiC = 800, 600 e 300 mesh) are analyzed on surface finishing of stainless steel AISI 420 flat workpieces submitted to the lapgrinding process. The best results, obtained after 10 minutes of machining, were: average surface roughness (Ra) 1.92 nm; 1.19 mu m flatness deviation of 25.4 mm diameter workpieces and mirrored surface finishing. Given the surface quality achieved, the lapgrinding process can be included among the ultra-precision finishing processes and, depending on the application, the steps of lapping followed by polishing can be replaced by the proposed abrasive process.

Surface finishing of flat pieces when submitted to lapping kinematics on abrasive disc dressed under several overlap factors

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

Surface characterization of Ti-7.5Mo alloy modified by biomimetic method

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

Surface Integrity Analysis when Milling Ultrafine-grained Steels

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

Maxillary Bone Defect Reconstruction Using Porous Polyethylene Implants

Purpose: The aim of this study was to evaluate the bone repair process in the maxillary sinus in monkeys treated with high-density porous polyethylene (Medpor)Methods: Four capuchin monkeys (Cebus apella) were submitted to bilateral horizontal osteotomies in the anterior wall of the maxillary sinus and divided into 2 groups: control group, left side with no implants, and porous polyethylene group, right side with Medpor. After a period of 145 days after implant placement, the maxillae were removed for histologic and histometric analyses.Results: Bone repair in osteotomized areas took place by connective tissue in 58.5% and 58.7% in the control group and the porous polyethylene group, respectively. In the contact surface with Medpor, bone repair occurred in 41.3%.Conclusions: Medpor was not reabsorbed within the period of this study and allowed bone repair surrounding it. The porous polyethylene constitutes a feasible alternative for bone defect reconstruction.

Vortices in superconductors with a columnar defect: Finite size effects

In the present work we investigate the behavior of a vortex in a long superconducting cylinder near to a columnar defect at the center. The derivations of the local magnetic field distribution and the Gibbs free energy will be carried out for a cylinder and a cavity of arbitrary sizes. From the general expressions, it is considered two particular limits: one in which the radius of the cavity is very small but the radius of the superconducting cylinder is kept finite; and one in which the radius of the superconducting cylinder is taken very large (infinite) but the radius of the cavity is kept finite. In both cases the maximum number of vortices which are allowed in the cavity is determined. In addition, the surface barrier field for flux entrance into the cavity is calculated. (c) 2005 Elsevier B.V. All rights reserved.

Response of rat bone marrow cells to commercially pure titanium submitted to different surface treatments

Objectives. Alterations in the commercially pure titanium (cpTi) surface may be undertaken to improve its biological properties. The aim of this study is to investigate the biocompatibility of cpTi submitted to different surface treatments.Methods. The cpTi surfaces were prepared so that machined and blasted surfaces, either acid etched or not, were compared using rat bone marrow cells cultured to differentiated into osteoblast. For attachment evaluation, cells were cultured for 4 and 24 h. Cell morphology was evaluated after 3 days. After 7, 14, and 21 days cell proliferation was evaluated. Total protein content and alkaline phosphatase (ALP) activity were evaluated after 14 and 21 days. For bone-like nodule formation, cells were cultured for 21 days. Data were compared by analysis of variance.Results. Cell attachment, cell morphology, cell proliferation, and ALP activity were not affected by surface treatments. Total. protein content was reduced by blasted and acid etched surface. Bone-Like nodule formation was significantly reduced by blasted, acid etched, and a combination of both blasted and acid etched surfaces.Conclusions. Based on these results, it can be suggested that cpTi surfaces that were submitted only to machining treatment favor the final event of osteoblastic differentiation of the rat bone marrow cells, evidenced by increased bone-Like nodule formation. (C) 2003 Elsevier B.V. Ltd. All rights reserved.

Effects of milling condition on the surface integrity of hot forged steel

This paper presents a study on the influence of milling condition on workpiece surface integrity focusing on hardness and roughness. The experimental work was carried out on a CNC machining center considering roughing and finishing operations. A 25 mm diameter endmill with two cemented carbide inserts coated with TiN layer were used for end milling operation. Low carbon alloyed steel Cr-Mo forged at 1200 degrees C was used as workpiece on the tests. Two kinds of workpiece conditions were considered, i.e. cur cooled after hot forging and normalized at 950 degrees C for 2 h. The results showed that finishing operation was able to significantly decrease the roughness by at least 46% without changing the hardness. on the other hand, roughing operation caused an increase in hardness statistically significant by about 6%. The machined surface presented deformed regions within feed marks, which directly affected the roughness. Surface finish behavior seems to correlate to the chip ratio given the decrease of 25% for roughing condition, which damaged the chip formation. The material removal rate for finishing operation 41% greater than roughing condition demonstrated to be favorable to the heat dissipation and minimized the effect on material hardness.

The minimum quantity of lubricant (MQL) technique in the surface grinding of steel

This research aimed to analyze the viability of the minimum quantity of lubricant (MQL) technique towards different methods of lubri-refrigeration in surface grinding of steel, considering process quality, wheel life and the viability of using cutting fluids The proposal methods were the conventional (abundant fluid flow), the minimum quantity lubrication (MQL) and the optimized method with Webster nozzle (rounded) This analysis was carried out in equal machining conditions, through the assessment of variables such as grinding force, surface roughness, G ratio (volume of removed material/volume of wheel wear), and microhardness The results showed the possibility of improvement of the grinding process Besides, there is the opportunity for production of high quality workpieces with lower costs The MQL technique showed efficiency in machining with lower depths of cut The optimized method with Webster nozzle applies the fluid in a rational way, without considerable waste Hence, the results show that industry can rationalize and optimize the application of cutting fluids, avoiding inappropriate disposal, inadequate use and consequently environment pollution

Advanced ceramics: Evaluation of the mechanism of stock removal and ground surface quality

The aim of this work is to evaluate the mechanism of stock removal and the ground surface quality of advanced ceramics grounded by a plane tangential grinding process with diamond grinding wheels. The analysis of the grinding performance was done regarding the cutting surface wear behavior of the grinding wheel for ceramic workpieces. The discussion about the results emphasized the wear mechanism of the grinding wheel cutting surface and the cutting phenomenology of the grinding process. The grounded surface was evaluated using Scanning Electron Microscopy (SEM). © 1999 Society of Automotive Engineers, Inc.

Surface amorphization in diamond turning of silicon crystal investigated by transmission electron microscopy

Silicon crystal exhibits a ductile regime during machining prior to the onset of fracture when appropriate cutting conditions are applied. The present study shows that the ductile regime is a result of a phase transformation which is indirectly evidenced by the amorphous phase detected in the machined surface. Transmission electron microscopy (TEM) planar view studies were successfully performed on monocrystalline silicon (1 0 0) single point diamond turned. TEM electron diffraction patterns show that the machined surface presents diffuse rings along with traces of crystalline material. This is attributed to crystalline silicon immersed in an amorphous matrix. Furthermore, only diffuse rings in the diffraction patterns of the ductile chip are detected, indicating that it is totally amorphous. © 2000 Elsevier Science B.V. All rights reserved.