Redes neurais: aplicação no monitoramento da vida de ferramentas de corte

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Usinagem a verde voltada à melhoria da distorção e acabamento superficial de cerâmicas sinterizadas

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Aprimoramento da técnica da mínima quantidade de lubrificante (MQL) no processo de retificação cilíndrica externa de mergulho de aços endurecidos

Pós-graduação em Ciência e Tecnologia de Materiais - FC

Proposição de um novo método de medição do desgaste em ferramentas de corte empregadas em operações de fresamento da madeira

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Avanços no torneamento utilizando um porta-ferramentas refrigerado internamente com fluido em mudança de fase

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

Estudo da influência da aplicação do fluido de corte no torneamento da liga de alumínio AA7075

One of the ways to minimize the effects of unproductive time caused by tool wear can be achieved by introducing an efficient system of lubrication and cooling in the process. However, in the last decade the research had the goal to restrict the maximum use of refrigerants and / or lubricants in metal-mechanical production. The important factors that justify this procedure include the operational costs of production, ecological issues, and the legal requirements of environmental conservation and preservation of human health. The purpose of the proposed work is the study of machining by turning with the focus on the influence caused by the application of cutting fluid in several ways of application (abundant and MQF) and also by comparing the results obtained by machining without the presence of fluid . For this purpose, the turning tests are conducted using an aluminum alloy (AA 7075). The response variables to be analyzed were obtained from the roughness (Ra and Ry), the stresses presented (VB) and their progression in relation to the cutting length achieved, the type of chip formed, in addition to changes in the degree of finish (roughness) presented by the turned parts. The results of this study should provide more detailed information about the actual influence of cutting fluids in turning this alloy, which are characterized by high rates of deformation when the formation of damaging your chip machining and also the quality of surface generated. Therefore, it is expected to provide subsidies to promote the optimization of machining this alloy making the most of the role of cutting fluid

Contribuição ao estudo do desgaste de bedames na usinagem de ligas de alumínio-silício

Pós-graduação em Engenharia Mecânica - FEIS

Análise do acabamento superficial e força de corte no torneamento de alumina a verde

In experimental conditions, cutting forces were studied during turning of green alumina billets, including their correlation with surface aspects of the workpiece. The correlation between cutting power and the removal rate are important parameters for defining the design of ceramic products, since inadequate parameters can produce excessive surface damage to the workpiece. This study examined the forces obtained during turning of alumina workpieces with 99.8% purity in their green state, by means of a three-point dynamometer, evaluating the cutting, feed and depth forces, using a cermet tool under constant machining conditions. Variables were compared with the forces, including surface finish, tool wear and temperature during machining. In the study, it was found that the depth of cut had no significant effect on the surface quality, and the cutting speed and feed influencing the finish. However, preliminary tests for selecting the cutting conditions showed that unsuitables cutting speeds and feeds generate severe damage to the workpiece surface. The best condition was 1.00 mm depth of cut, and the forces increasedfor with each pass performed, with the feed force the variable with greatest increases in relation to the cutting and depth forces, and wear of the cutting tool directly influenced the surface finish, generated by the highly abrasive nature of the alumina particles of the green compact. It is emphasized that the alumina in its green state showed high abrasive effect on the cutting tool during the turning process and the surface finishing of the green workpiece had a direct influence on the sintered workpiece.

Experimental and numerical study of heat transfer in hot machined workpiece using infrared radiation

One of the greatest problems found in machining is related to the cutting tool wear. A way for increasing the tool life points out to the development of materials more resistant to wear, such as PCBN inserts. However, the unit cost of these tools is considerable high, around 10 to 20 times compared to coated carbide insert, besides its better performance occurs in high speeds requiring modern machine tools. Another way, less studied is the workpiece heating in order to diminish the shear stress material and thus reduce the machining forces allowing an increase of tool life. For understanding the heat transfer influences by conduction in this machining process, a mathematical model was developed to allow a simplified numerical simulation, using the finite element method, in order to determine the temperature profiles inside the workpiece.

Efeito das diferentes direções de aplicação de jato de fluido de corte no torneamento de um aço de difícil usinagem

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Fresamento de aço para moldes e matrizes em condições criogênicas

Pós-graduação em Engenharia Mecânica - FEIS

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

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

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.

Avaliação do erro estático da ferramenta de uma máquina fresadora com arquitetura paralela.

Os mecanismos amplamente utilizados em aplicações industriais são de tipo serial, porém há algum tempo vem sendo desenvolvidos estudos sobre as vantagens que os mecanismos de arquitetura paralela oferecem em contraposição com os seriais. Rigidez, precisão, altas frequências naturais e velocidade são algumas características que os mecanismos paralelos atribuem a máquinas já consolidadas na indústria, destinadas principalmente nas operações de manipulação (pick and place). Nesse sentido, é relevante o estudo sobre a funcionalidade em outros tipos de operação como a usinagem e, particularmente o fresamento. Para isto, devem-se ainda explorar e desenvolver as capacidades dos mecanismos paralelos em relação à rigidez e à precisão nas operações mencionadas. Foi desenvolvido previamente o projeto e montagem do protótipo de uma máquina fresadora de arquitetura paralela. Também aracterizado pela redundância na atuação para o posicionamento da ferramenta. Com este intuito, pretende-se no trabalho atual, avaliar o erro estático de posicionamento da ferramenta por métodos experimentais, quantificar os deslocamentos, realizar um mapeamento experimental em diversas configurações dos membros. Por outro lado, pretende-se adaptar um modelo numérico simplificado que possa prever as deformações elásticas em diversas configurações, que contemple o efeito de juntas lineares flexíveis e que de alguma forma ajude a identificar as principais fontes de erro. Para tal, foram elaboradas rotinas de programação que através da cinemática inversa e o uso do método dos elementos finitos tentem prever o que de fato acontece nos experimentos. Foi proposta também uma implementação alternativa para o controle do mecanismo através de um software CNC e a conversão de coordenadas cartesianas em coordenadas dos atuadores, isto ajudaria na geração do código G. Finalmente, foram elaboradas algumas trajetórias que tentam avaliar a exatidão e repetitividade do mecanismo além de descrever outras trajetórias livres.