Avaliação dos aspectos de processo no torneamento de madeiras tratadas termicamente

Pós-graduação em Engenharia Mecânica - FEG

Usinagem do alumínio da classe 6005 com uso de ferramenta cerâmica

The machining process is so much important in the economic world. Many machining parameters have been studied to maximize results, in terms of cost and lifetime. (decrease of cutting tool wear, improved surface finish, among others). The objective of this study is to evaluate the wear of a ceramic tool in the machining of the aluminum alloy 6005 A. The analysis of the wear of the cutting tools is very important due to its big impact on the final finishing of the piece as a whole. The evaluation took place in two stages, first it was done a detailed study of the literature of the whole machining process, where the study of the formation and swarf classification were among the most important steps in this phase. The second step consisted in the machining of the piece of aluminum 6005 A with a ceramic cutting tool constituded of aluminum oxide and magnesium oxide with silicon carbide impregnation. The swarf generated in this process was then photographed with a Zeiss optical microscope and analyzed for its size and shape. Through this comparison it was concluded that the swarf are generated shear swarfs, shaped like a tangled, fragmented and arcs connected, thus classifying the material as medium difficulty machining. Through the image analysis tool it was concluded that the parameter of lower wear was the: Vc = 500m / min, f = 0.10mm / rev and ap = 0.5mm

Estudo da utilização de ferramentas a base de nitreto de silício (Si3N4) e alumina (Al2O3) na usinagem do ferro fundido vermicular

Machining is one of the most commonly manufacturing processes used in the modern world, consuming millions of dollars annually. Because of this, it is crucial for the automotive industry to reduce costs on their heat-resistant alloy machining processes, such as compacted graphite iron (CGI), which has shown an increasing trend of its application in diesel engine blocks, brakes disks, among other applications, due to its superior mechanical properties to gray cast iron. Despite this advantage, its use is still limited due to its difficulty of machining, moreover, cutting tools are displayed as the main factor in increasing the machining cost. Seeking an alternative to a better machinability of CGI, this paper aims to study two types of ceramic tools developed in Brazil, and benchmark their performance by dry turning. For this, were used CGI class 450 and two tools: ceramic of silicon nitride (Si3N4) and alumina-based (Al2O3), with a cutting speed (Vc) of 300, 400 and 500 m / min; feed (f) of 0.2 mm / rev and depth of cut (ap) of 0.5 mm, using three replicates and starting with new cutting edges. The results showed that the Al2O3 tool had the best performance in Vc of 500 m / min, while the Si3N4 tool had the best results in Vc of 300 m / min. This can be explained by the tool of Si3N4 based include soft intergranular phase, called amorphous, while alumina has higher abrasion resistance due to its high refractoriness. The results make it clear that the tools have significant potential for machining of compacted graphite iron, being necessary a strict control of the cutting parameters used

Usinagem do alumínio da classe 6005 com uso de ferramenta cerâmica

The machining process is so much important in the economic world. Many machining parameters have been studied to maximize results, in terms of cost and lifetime. (decrease of cutting tool wear, improved surface finish, among others). The objective of this study is to evaluate the wear of a ceramic tool in the machining of the aluminum alloy 6005 A. The analysis of the wear of the cutting tools is very important due to its big impact on the final finishing of the piece as a whole. The evaluation took place in two stages, first it was done a detailed study of the literature of the whole machining process, where the study of the formation and swarf classification were among the most important steps in this phase. The second step consisted in the machining of the piece of aluminum 6005 A with a ceramic cutting tool constituded of aluminum oxide and magnesium oxide with silicon carbide impregnation. The swarf generated in this process was then photographed with a Zeiss optical microscope and analyzed for its size and shape. Through this comparison it was concluded that the swarf are generated shear swarfs, shaped like a tangled, fragmented and arcs connected, thus classifying the material as medium difficulty machining. Through the image analysis tool it was concluded that the parameter of lower wear was the: Vc = 500m / min, f = 0.10mm / rev and ap = 0.5mm

Estudo da utilização de ferramentas a base de nitreto de silício (Si3N4) e alumina (Al2O3) na usinagem do ferro fundido vermicular

Machining is one of the most commonly manufacturing processes used in the modern world, consuming millions of dollars annually. Because of this, it is crucial for the automotive industry to reduce costs on their heat-resistant alloy machining processes, such as compacted graphite iron (CGI), which has shown an increasing trend of its application in diesel engine blocks, brakes disks, among other applications, due to its superior mechanical properties to gray cast iron. Despite this advantage, its use is still limited due to its difficulty of machining, moreover, cutting tools are displayed as the main factor in increasing the machining cost. Seeking an alternative to a better machinability of CGI, this paper aims to study two types of ceramic tools developed in Brazil, and benchmark their performance by dry turning. For this, were used CGI class 450 and two tools: ceramic of silicon nitride (Si3N4) and alumina-based (Al2O3), with a cutting speed (Vc) of 300, 400 and 500 m / min; feed (f) of 0.2 mm / rev and depth of cut (ap) of 0.5 mm, using three replicates and starting with new cutting edges. The results showed that the Al2O3 tool had the best performance in Vc of 500 m / min, while the Si3N4 tool had the best results in Vc of 300 m / min. This can be explained by the tool of Si3N4 based include soft intergranular phase, called amorphous, while alumina has higher abrasion resistance due to its high refractoriness. The results make it clear that the tools have significant potential for machining of compacted graphite iron, being necessary a strict control of the cutting parameters used

Influence of effective number of pulses on the morphological structure of teeth and bovine femur after femtosecond laser ablation

Femtosecond lasers have been widely used in laser surgery as an instrument for contact-free tissue removal of hard dental, restorative materials, and osseous tissues, complementing conventional drilling or cutting tools. In order to obtain a laser system that provides an ablation efficiency comparable to mechanical instruments, the laser pulse rate must be maximal without causing thermal damage. The aim of this study was to compare the different morphological characteristics of the hard tissue after exposure to lasers operating in the femtosecond pulse regime. Two different kinds of samples were irradiated: dentin from human extracted teeth and bovine femur samples. Different procedures were applied, while paying special care to preserving the structures. The incubation factor S was calculated to be 0.788 +/- 0.004 for the bovine femur bone. These results indicate that the incubation effect is still substantial during the femtosecond laser ablation of hard tissues. The plasma-induced ablation has reduced side effects, i.e., we observe less thermal and mechanical damage when using a superficial femtosecond laser irradiation close to the threshold conditions. In the femtosecond regime, the morphology characteristics of the cavity were strongly influenced by the change of the effective number of pulses. (C) 2012 Society of Photo-Optical Instrumentation Engineers (SPIE). [DOI: 10.1117/1.JBO.17.4.048001]

Archeological Investigations at the Big Creek Lake Site (24RA34)

In August 1977 excavation was conducted at the Big Creek Lake site -24RA34- at the outlet of the 91g Creek Lakes, Selway-Bitterroot Wilderness Area, Ravalli County, Montana. The site contained shallow, disturbed deposits and lacks any statisgraphic separation. One of these occupations was identified by a projectile point type not previously reported from the area. This was termed Big Creek Corner Notched and its temporal affiliation is not precisely known. Comparative material from Colorado and Alberta suggest either Early Archaic or Late Archaic affiliation. The occupations exemplified by Big Creek Corner Notched points and by Pelican Lake-Elko points (Late Archaic 1000 B.B – A.D. 200) were the most prevalent at the site. Less intensive occupations are by ·Middle Plains Archaic McKean points and Late Prehistoric small side notche arrow points. Microscopic analysis of tool working edges shows several of the projectile point forms were used as multi-functional implements. especially as butchering tools. Many of the types of chipped stone recovered from the site are from known sources in western Montana; indicating group movements within the eastern portion of the Intermountain region. Based on the numerous projectile points and cutting tools, the site is interpreted as a seasonally occupied base camp for hunters.

Estudo da geometria da aresta de corte de ferramentas aplicadas ao torneamento de superligas à base de níquel com alta velocidade de corte

Pesquisadores e indústrias de todo o mundo estão firmemente comprometidos com o propósito de fazer o processo de usinagem ser precisamente veloz e produtivo. A forte concorrência mundial gerou a procura por processos de usinagem econômicos, com grande capacidade de produção de cavacos e que produzam peças com elevada qualidade. Dentre as novas tecnologias que começaram a ser empregadas, e deve tornar-se o caminho certo a ser trilhado na busca da competitividade em curto espaço de tempo, está a tecnologia de usinagem com altas velocidades (HSM de High Speed Machining). A tecnologia HSM surge como componente essencial na otimização dos esforços para manutenção e aumento da competitividade global das empresas. Durante os últimos anos a usinagem com alta velocidade tem ganhado grande importância, sendo dada uma maior atenção ao desenvolvimento e à disponibilização no mercado de máquinas-ferramentas com rotações muito elevadas (20.000 - 100.000 rpm). O processo de usinagem com alta velocidade está sendo usado não apenas para ligas de alumínio e cobre, mas também para materiais de difícil usinabilidade, como os aços temperados e superligas à base de níquel. Porém, quando se trata de materiais de difícil corte, têm-se observado poucas publicações, principalmente no processo de torneamento. Mas, antes que a tecnologia HSM possa ser empregada de uma forma econômica, todos os componentes envolvidos no processo de usinagem, incluindo a máquina, o eixo-árvore, a ferramenta e o pessoal, precisam estar afinados com as peculiaridades deste novo processo. No que diz respeito às máquinas-ferramenta, isto significa que elas têm que satisfazer requisitos particulares de segurança. As ferramentas, devido à otimização de suas geometrias, substratos e revestimentos, contribuem para o sucesso deste processo. O presente trabalho objetiva estudar o comportamento de diversas geometrias ) de insertos de cerâmica (Al2O3 + SiCw e Al2O3 + TIC) e PCBN com duas concentrações de CBN na forma padrão, assim como modificações na geometria das arestas de corte empregadas em torneamento com alta velocidade em superligas à base de níquel (Inconel 718 e Waspaloy). Os materiais foram tratados termicamente para dureza de 44 e 40 HRC respectivamente, e usinados sob condição de corte a seco e com utilização da técnica de mínima quantidade de lubrificante (minimal quantity lubricant - MQL) visando atender requisitos ambientais. As superligas à base de níquel são conhecidas como materiais de difícil usinabilidade devido à alta dureza, alta resistência mecânica em alta temperatura, afinidade para reagir com materiais da ferramenta e baixa condutividade térmica. A usinagem de superligas afeta negativamente a integridade da peça. Por essa razão, cuidados especiais devem ser tomados para assegurar a vida da ferramenta e a integridade superficial de componentes usinados por intermédio de controle dos principais parâmetros de usinagem. Experimentos foram realizados sob diversas condições de corte e geometrias de ferramentas para avaliação dos parâmetros: força de corte, temperatura, emissão acústica e integridade superficial (rugosidade superficial, tensão residual, microdureza e microestrutura) e mecanismos de desgaste. Mediante os resultados apresentados, recomenda-se à geometria de melhor desempenho nos parâmetros citados e confirma-se a eficiência da técnica MQL. Dentre as ferramentas e geometrias testadas, a que apresentou melhor desempenho foi a ferramenta cerâmica CC650 seguida da ferramenta cerâmica CC670 ambas com formato redondo e geometria 2 (chanfro em T de 0,15 x 15º com raio de aresta de 0,03 mm).

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 Kinematics of interference mechanisms in certain machining operations

The mechanism of "Helical Interference" in milled slots is examined and a coherent theory for the geometry of such surfaces is presented. An examination of the relevant literature shows a fragmented approach to the problem owing to its normally destructive nature, so a complete analysis is developed for slots of constant lead, thus giving a united and exact theory for many different setting parameters and a range of cutter shapes. For the first time, a theory is developed to explain the "Interference Surface" generated in variable lead slots for cylindrical work and attention is drawn to other practical surfaces, such as cones, where variable leads are encountered. Although generally outside the scope of this work, an introductory analysis of these cases is considered in order to develop the cylindrical theory. Special emphasis is laid upon practical areas where the interference mechanism can be used constructively and its application as the rake face of a cutting tool is discussed. A theory of rake angle for such cutting tools is given for commonly used planes, and relative variations in calculated rake angle between planes is examined. Practical tests are conducted to validate both constant lead and variable lead theories and some design improvements to the conventional dividing head are suggested in order to manufacture variable lead workpieces, by use of a "superposed" rotation. A prototype machine is manufactured and its kinematic principle given for both linear and non-linearly varying superposed rotations. Practical workpieces of the former type are manufactured and compared with analytical predictions,while theoretical curves are generated for non-linear workpieces and then compared with those of linear geometry. Finally suggestions are made for the application of these principles to the manufacture of spiral bevel gears, using the "Interference Surface" along a cone as the tooth form.

Inspection of parts with complex geometry and welds with structural health monitoring techniques

Structural Health Monitoring (SHM) systems were developed to evaluate the integrity of a system during operation, and to quickly identify the maintenance problems. They will be used in future aerospace vehicles to improve safety, reduce cost and minimize the maintenance time of a system. Many SHM systems were already developed to evaluate the integrity of plates and used in marine structures. Their implementation in manufacturing processes is still expected. The application of SHM methods for complex geometries and welds are two important challenges in this area of research. This research work started by studying the characteristics of piezoelectric actuators, and a small energy harvester was designed. The output voltages at different frequencies of vibration were acquired to determine the nonlinear characteristics of the piezoelectric stripe actuators. The frequency response was evaluated experimentally. AA battery size energy harvesting devices were developed by using these actuators. When the round and square cross section devices were excited at 50 Hz frequency, they generated 16 V and 25 V respectively. The Surface Response to Excitation (SuRE) and Lamb wave methods were used to estimate the condition of parts with complex geometries. Cutting tools and welded plates were considered. Both approaches used piezoelectric elements that were attached to the surfaces of considered parts. The variation of the magnitude of the frequency response was evaluated when the SuRE method was used. The sum of the square of the differences was calculated. The envelope of the received signal was used for the analysis of wave propagation. Bi-orthogonal wavelet (Binlet) analysis was also used for the evaluation of the data obtained during Lamb wave technique. Both the Lamb wave and SuRE approaches along with the three methods for data analysis worked effectively to detect increasing tool wear. Similarly, they detected defects on the plate, on the weld, and on a separate plate without any sensor as long as it was welded to the test plate.

An experimental study of micro-end-milling operations

Cutting tools less than 2mm diameter can be considered as micro-tool. Microtools are used in variety of applications where precision and accuracy are indispensable. In micro-machining operations, a small amount of material is removed and very small cutting forces are created. The small cross sectional area of the micro-tools drastically reduces their strength and makes their useful life short and unpredictable; so cutting parameters should be selected carefully to avoid premature tool breakage. The main objective of this study is to develop new techniques to select the optimal cutting conditions with minimum number of experiments and to evaluate the tool wear in machining operations. Several experimental setups were prepared and used to investigate the characteristics of cutting force and AE signals during the micro-end-milling of different materials including steel, aluminum and graphite electrodes. The proposed optimal cutting condition selection method required fewer experiments than conventional approaches and avoided premature tool breakage. The developed tool wear monitoring technique estimated the used tool life with ±10% accuracy from the machining data collected during the end-milling of non-metal materials.

Influência da utilização do fluido de corte com adição de grafeno na temperatura de usinagem e formação de rebarba no processo de micro fresamento

As time passed, humanity needed the development of new materials used in various activities. High strength materials such as titanium and Inconel for example, had been studied because they are widely used for implants in biomedicine, as well as their use in aerospace and automotive industries. Because of its thermal and mechanical properties, these materials are considered difficult to machine, promoting a rapid wear of cutting tools, primarily caused by the high temperatures in machining. With the development of new materials has emerged the need of developing new manufacturing processes. One of today’s innovative processes is the micro-manufacturing. Being a process with a defined cutting tool geometry, burr formation is a constant and undesirable phenomenon formed during the machininig process. Being detrimental to the manufacturing process, overspending deburring operations are constantly employed leading to increase the aggregate cost to the manufactured material. Assembly components are also impaired if there is no control of the burr, with consequences including the disposal of components due to the occurence of this phenomenon. This paper presents the study of micro-milling Inconel 718, investigating influential parameters in the formation of burrs in order to minimize the occurrence of this phenome non. Different feed rates per tooth and cutting speed are evaluated, and different cutting fluids with different methods of applying the fluid. Adding graphene to cutting fluids was considered as a variable to be investigated, which is considered an excellent solid lubricant, in addition to increasing the thermal conductivity of the cooling solution (AZIMI; MOZAF FARI, 2015). The micro-milling temperature was evaluated in the present work. It was observed a new phenomenon that causes the machined surface temperature decreases below room temperature when using the solution water + oil. This phenomenon is explained in further chapters. In order to unravel this phenomenon, a new test was proposed and, from this test, it can be concluded, comparatively, which cutting fluid has a better cooling property.Using cutting fluid with different thermal properties has shown influence when analy zing burr formation and reducing machining temperature.

Tool wear and surface integrity analysis of machined heat treated selective laser melted Ti-6Al-4V

In this study, the tool wear and surface integrity during machining of wrought and Selective LaserMelted (SLM) titanium alloy (after heat treatment) are studied. Face turning trails were carried out onboth the materials at different cutting speeds of 60,120 and 180 m/min. Cutting tools and machinedspecimens collected are characterized using scanning electron microscope, surface profiler and opticalmicroscope to study the tool wear, machined surface quality and machining induced microstructuralalterations. It was found that high cutting speeds lead to rapid tool wear during machining of SLMTi-6Al-4V materials. Rapid tool wear observed at high cutting speeds in machining SLM Ti-6Al-4Vresulted in damaging the surface integrity by 1) Deposition of chip/work material on the machinedsurface giving rise to higher surface roughness and 2) Increasing the depth of plastic deformationon the machined sub surface.

Machinability of metallic and ceramic biomaterials : a review

The machining process is the most common method for metal cutting, especially in the fabrication of biomaterials and artificial implants. In modern industry, the goal of production is to manufacture products at a low cost, with the highest quality in the shortest time. The main focus of the research presented here is to provide a review of the machinability of metallic and ceramic biomaterials in traditional machining processes, such as turning, milling and grinding. Thereafter, machining strategies, machinability and surface characteristics post machining are discussed. To provide a better understanding of the machining process, various cutting tools and fluids are analysed. Finally, the current research gap and directions of prospect investigations are highlighted.