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).

Lathe and planer tools...

Cutting tools for planer and lathe, by W.J. Kaup.--Boring tools, by W.J. Kaup.--Shape of standard shop tools.--Straight and circular forming tools, by J.M. Stabel and G.D. Hayden.

The oxy-acetylene handbook : a manual on oxy-acetylene welding and cutting procedures.

Includes index.

Deep hole drilling with twist drills: aspects of the CNC process and its real time monitoring and adaptive control

Deep hole drilling is one of the most complicated metal cutting processes and one of the most difficult to perform on CNC machine-tools or machining centres under conditions of limited manpower or unmanned operation. This research work investigates aspects of the deep hole drilling process with small diameter twist drills and presents a prototype system for real time process monitoring and adaptive control; two main research objectives are fulfilled in particular : First objective is the experimental investigation of the mechanics of the deep hole drilling process, using twist drills without internal coolant supply, in the range of diarneters Ø 2.4 to Ø4.5 mm and working length up to 40 diameters. The definition of the problems associated with the low strength of these tools and the study of mechanisms of catastrophic failure which manifest themselves well before and along with the classic mechanism of tool wear. The relationships between drilling thrust and torque with the depth of penetration and the various machining conditions are also investigated and the experimental evidence suggests that the process is inherently unstable at depths beyond a few diameters. Second objective is the design and implementation of a system for intelligent CNC deep hole drilling, the main task of which is to ensure integrity of the process and the safety of the tool and the workpiece. This task is achieved by means of interfacing the CNC system of the machine tool to an external computer which performs the following functions: On-line monitoring of the drilling thrust and torque, adaptive control of feed rate, spindle speed and tool penetration (Z-axis), indirect monitoring of tool wear by pattern recognition of variations of the drilling thrust with cumulative cutting time and drilled depth, operation as a data base for tools and workpieces and finally issuing of alarms and diagnostic messages.

Effect of thermal and mechanical processing on tensile properties of powder formed 2124 aluminium and 2124 Al-SiC p metal matrix composite

The aging responses of 2124 Al-SiC p metal matrix composite (MMC) and unreinforced matrix alloy are studied and related to variations in tensile properties. The MMC is aged from Wo starting conditions: (i) stretched and naturally aged and (ii) re-solution treated. Accelerated aging occurs in both MMC conditions compared with unreinforced alloy. Tensile strengths and elastic moduli are improved in the MMC compared with the alloy, but ductility is reduced. Stretched MMC exhibits higher strength but lower ductility and modulus than re-solutioned MMC. The re-solutioned MMC fails by microvoid coalescence in low aging conditions, and by void nucleation and shear in high aging conditions. Failure of the stretched MMC initiates at the surface at specimen shoulders, illustrating the increased notch sensitivity of this condition, and propagates via a zigzag shear fracture mode. Zigzag facet size increases on gross aging. Particle fracture occurs during tensile failure, but also before testing as a result of the manufacturing process. © 1995 The Institute of Materials.

Structure, Morphology, and Electrochemical Properties of Transition Metal Oxide, Hydroxide, and Phosphate Nanomaterials for Energy Storage

Energy storage technologies are crucial for efficient utilization of electricity. Supercapacitors and rechargeable batteries are of currently available energy storage systems. Transition metal oxides, hydroxides, and phosphates are the most intensely investigated electrode materials for supercapacitors and rechargeable batteries due to their high theoretical charge storage capacities resulted from reversible electrochemical reactions. Their insulating nature, however, causes sluggish electron transport kinetics within these electrode materials, hindering them from reaching the theoretical maximum. The conductivity of these transition metal based-electrode materials can be improved through three main approaches; nanostructuring, chemical substitution, and introducing carbon matrices. These approaches often lead to unique electrochemical properties when combined and balanced.

Ethanol-mediated solvothermal synthesis we developed is found to be highly effective for controlling size and morphology of transition metal-based electrode materials for both pseudocapacitors and batteries. The morphology and the degree of crystallinity of nickel hydroxide are systematically changed by adding various amounts glucose to the solvothermal synthesis. Nickel hydroxide produced in this manner exhibited increased pseudocapacitance, which is partially attributed to the increased surface area. Interestingly, this morphology effect on cobalt doped-nickel hydroxide is found to be more effective at low cobalt contents than at high cobalt contents in terms of improving the electrochemical performance.

Moreover, a thin layer of densely packed nickel oxide flakes on carbon paper substrate was successfully prepared via the glucose-assisted solvothermal synthesis, resulting in the improved electrode conductivity. When reduced graphene oxide was used for conductive coating on as-prepared nickel oxide electrode, the electrode conductivity was only slightly improved. This finding reveals that the influence of reduced graphene oxide coating, increasing the electrode conductivity, is not that obvious when the electrode is already highly conductive to begin with.

We were able to successfully control the interlayer spacing and reduce the particle size of layered titanium hydrogeno phosphate material using our ethanol-mediated solvothermal reaction. In layered structure, interlayer spacing is the key parameter for fast ion diffusion kinetics. The nanosized layered structure prepared via our method, however, exhibited high sodium-ion storage capacity regardless of the interlayer spacing, implying that interlayer space may not be the primary factor for sodium-ion diffusion in nanostructured materials, where many interstitials are available for sodium-ion diffusion.

Our ethanol-mediated solvothermal reaction was also effective for synthesis of NaTi2(PO4)3 nanoparticles with uniform size and morphology, well connected by a carbon nanotube network. This composite electrode exhibited high capacity, which is comparable to that in aqueous electrolyte, probably due to the uniform morphology and size where the preferable surface for sodium-ion diffusion is always available in all individual particles.

Fundamental understandings of the relationship between electrode microstructures and electrochemical properties discussed in this dissertation will be important to design high performance energy storage system applications.

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.

Manufacturing challenges with fabrication of large size mechanical harmonic drives

In truck manufacturing, the exhaust and air inlet pipes are specialized equipment that requires highly skilled, heavy machinery and small batch production methods. This paper describes a project to develop the computer numerically controlled (CNC) pipe bending process for a truck component manufacturer. The company supplies a huge range of heavy duty truck parts to the domestic market and is a significant supplier in Australia. The company has been using traditional methods of machine assisted manual pipe bending techniques. In a drive of continuous improvement, the company has acquired a pre-owned CNC bending machine capable of bending pipes automatically up to 25 bends. However, due to process mismatch, this machine is only used for single bending operation. The researchers studied the bending system and changed the manufacturing process. Using an example exhaust pipe as the benchmark, a significant drop of manufacturing lead time from 70 minutes to 40 minutes for each pipe was demonstrated. There was also a decrease of material cost due to the multiple bends part in one piece without cutting excessive materials for each single bend like it used to be.

Hybrid antibacterial fabrics with extremely high aspect ratio Ag/AgTCNQ nanowires

This study reports the synthesis of extremely high aspect ratios (>3000) organic semiconductor nanowires of Ag–tetracyanoquinodimethane (AgTCNQ) on the surface of a flexible Ag fabric for the first time. These one-dimensional (1D) hybrid Ag/AgTCNQ nanostructures are attained by a facile, solution-based spontaneous reaction involving immersion of Ag fabrics in an acetonitrile solution of TCNQ. Further, it is discovered that these AgTCNQ nanowires show outstanding antibacterial performance against both Gram negative and Gram positive bacteria, which outperforms that of pristine Ag. The outcomes of this study also reflect upon a fundamentally important aspect that the antimicrobial performance of Ag-based nanomaterials may not necessarily be solely due to the amount of Ag+ ions leached from these nanomaterials, but that the nanomaterial itself may also play a direct role in the antimicrobial action. Notably, the applications of metal-organic semiconducting charge transfer complexes of metal-7,7,8,8-tetracyanoquinodimethane (TCNQ) have been predominantly restricted to electronic applications, except from our recent reports on their (photo)catalytic potential and the current case on antimicrobial prospects. This report on growth of these metal-TCNQ complexes on a fabric not only widens the window of these interesting materials for new biological applications, it also opens the possibilities for developing large-area flexible electronic devices by growing a range of metal-organic semiconducting materials directly on a fabric surface.

Effect of overload cycles on thin steel roof claddings during cyclonic winds

During an investigation on thin steel roof claddings under simulated cyclonic wind loading, it was found that trapezoidal roof claddings behaved quite differently to corrugated (arc and tangent type) roof claddings due to the presence of overload cycles. The overload cycles caused a reduction in fatigue life for corrugated roofing whereas the reverse occurred for trapezoidal roofing. This contrasting behavior of the two crest-fixed roof claddings was investigated using small scale roofing models instead of the commonly used large scale two-span roof claddings. It was found that overload cycles formed a weaker locally dimpled mechanism around the fastener holes of corrugated roofing and thus accelerated the fatigue-caused pull-through failure. In contrast, a stronger deformed shape was formed in trapezoidal roofing which delayed the pull-through failure. Both laboratory testing and finite element analysis of small scale models were used to study the contrasting behavior of roof claddings.

Genesis of workpiece roughness generated in surface grinding and polishing of metals

Assuming the grinding wheel surface to be fractal in nature, the maximum envelope profile of the wheel and contact deflections are estimated over a range of length scales. This gives an estimate of the 'no wear' roughness of a surface ground metal. Four test materials, aluminum, copper, titanium, and steel are surface ground and their surface power spectra were estimated. The departure of this power spectra from the 'no wear' estimates is studied in terms of the traction-induced wear damage of the surfaces. The surface power spectra in grinding are influenced by hardness and the power is enhanced by wear damage. No such correlation with hardness was found for the polished surface, the roughness of which is insensitive to mechanical properties and appears to be influenced by microstructure and physical properties of the material.

γ-Y2Si2O7, a machinable silicate ceramic: Mechanical properties and machinability

In this paper, the mechanical properties of bulk single-phase γ-Y2Si2O7 ceramic are reported. γ-Y2Si2O7 exhibits low shear modulus, excellent damage tolerance, and thus has a good machinability ready for metal working tools. To understand the underlying mechanism of machinability, drilling test, Hertzian contact test, and density functional theory (DFT) calculation are employed. Hertzian contact test demonstrates that γ-Y2Si2O7 is a "quasi-plastic" ceramic and the intrinsically weak interfaces contribute to its machinability. Crystal structure characteristics and DFT calculations of γ-Y2Si2O7 suggest that some weakly bonded planes, which involve Y-O bonds that can be easily broken, are the sources of the low shear deformation resistance and good machinability.

Self-interrupted regenerative turning

A preliminary study of self-interrupted regenerative turning is performed in this paper. To facilitate the analysis, a new approach is proposed to model the regenerative effect in metal cutting. This model automatically incorporates the multiple-regenerative effects accompanying self-interrupted cutting. Some lower dimensional ODE approximations are obtained for this model using Galerkin projections. Using these ODE approximations, a bifurcation diagram of the regenerative turning process is obtained. It is found that the unstable branch resulting from the subcritical Hopf bifurcation meets the stable branch resulting from the self-interrupted dynamics in a turning point bifurcation. Using a rough analytical estimate of the turning point tool displacement, we can identify regions in the cutting parameter space where loss of stability leads to much greater amplitude self-interrupted motions than in some other regions.

EVOLUTION OF DEFORMATION FIELDS IN PLOUGHING OF SAND

This paper reports on an experimental study on the ploughing or orthogonal cutting in sand. Plane strain cutting or ploughing experiments were carried out on model Ottawa sand while being imaged at high resolution. The images obtained were further processed using image analysis and the evolution of the velocity and deformation fields were obtained from these analysis. The deformation fields show the presence of a clear shear zone in which the sand accrues deformation. A net change in the direction of the velocity of the sand is also clearly visible. The effective depth of cut of the sand also increases with continuous cutting as the sand reposes on itself. This deformation mechanics at the incipient stages of cutting is similar to that observed in metal cutting.

Radially polarized and pulsed output from passively Q-switched Nd:YAG ceramic microchip laser

For the first time, to the best of our knowledge, a radially polarized laser pulse was produced from a passively Q-switched Nd:YAG ceramic microchip laser with a piece of Cr4+:YAG crystal as the saturable absorber and multilayer concentric subwavelength grating as the polarization-selective output coupler. The averaged laser power reached 450 mW with a slope efficiency of 30.2%. The laser pulse had a maximum peak power of 759 W, a minimum pulse duration of 86 ns, and a 6.7 kHz repetition rate at 3.7 W absorbed pump power. The polarization degree of the radially polarized pulse was measured to be as high as 97.4%. Such a radially polarized laser pulse with a high peak power and a short width is important to numerous applications such as metal cutting. (C) 2008 Optical Society of America