Estudi de la influència del lubricant en operacions de mecanització

Els processos de mecanitzat amb arrencament de ferritja consisteixen en arrencar contínuament petits fragments de material de la peça a la que es vol donar forma mitjançant les eines de tall. En treballar amb metalls, aquestes forces de tall són importants, i provoquen el desgast de les eines així com un escalfament important de l’eina i la peça. Per aquest motiu s’introdueixen els olis de tall, amb les principals funcions de refrigerar i lubricar. Tradicionalment, aquests olis de tall s’han subministrat a raig, quedant la zona de treball inundada. Els últims anys, degut a les millores tecnològiques i per intentar estalviar amb olis de tall, s’ha ideat un nou sistema anomenat mínima quantitat de lubricant, el qual subministra petites gotes d’oli, no soluble en aigua, dins un flux d’aire a pressió. Aquest sistema, a més, s’injecta prop de la zona de treball, on és estricament necessari. Aquest sistema redueix considerablement el consum d’oli de tall, i a més, augmenta l’eficiència de la lubricació. A part, elimina els posteriors tractaments per reciclar l’oli de tall un cop perd les seves propietats. Per aquest motiu, es pretén estudiar la utilització d’un mètode semblant al de la mínima quantitat de lubricant, subministrant el mateix oli de tall que s’utilitza convencionalment però polvoritzar per tal de convertir-lo en un aerosol

Contribución al desarrollo del proceso de selección de centros de mecanizado de alta velocidad, basado en parámetros tecnológicos y de productividad

La selección de centros de mecanizado de alta velocidad es un proceso complejo que requiere de mucha experiencia, puesto que en él intervienen un gran número de variables, tanto tecnológicas como económicas. Existen metodologías orientadas a seleccionar el centro de mecanizado óptimo, considerando únicamente una de estas dos tipologías de variables, sin embargo, esta tesis propone una metodología que contempla ambos tipos. Para ello se identifican las variables que tienen mayor influencia sobre los resultados del proceso de mecanizado, tanto desde un punto de vista de calidad de las piezas fabricadas como de la economía de la fabricación, y se propone un modelo de selección basado en los resultados de un trabajo experimental realizado sobre piezas de aluminio. Dicho modelo se implementa mediante redes neurales, cuyo entrenamiento se realiza en base a los resultados del trabajo experimental mencionado.

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.

An investigation into the mechanics of cutting using data from orthogonally cutting Nylon 66

Cutting force data for Nylon 66 has been examined in terms of various different models of cutting. Theory that includes significant work of separation at the tool tip was found to give the best correlation with experimental data over a wide range of rake angles for derived primary shear plane angle. A fracture toughness parameter was used as the measure of the specific work of separation. Variation in toughness with rake angle determined from cutting is postulated to be caused by mixed mode separation at the tool tip. A rule of mixtures using independently determined values of toughness in tension (mode 1) and shear (mode 11) is found to describe well the variation with rake angle. The ratio of modes varies with rake angle and, in turn, with the primary shear plane angle. Previous suggestions that cutting is a means of experimentally determining fracture toughness are now seen to be extended to identify the mode of fracture toughness as well.

Impacto das privatizações nas relações trabalhistas e sindicais - estudo comparativo de três casos ocorridos no sudeste brasileiro

O presente estudo discute o movimento das privatizações recentemente ocorridas e seus impactos nas relações trabalhistas e sindicais brasileiras. A discussão está focada em estudo de caso de três organizações, pertencentes a ramos de negócio diferentes e busca entender os reflexos havidos nas relações entre os agentes SOCIaIS envolvidos: empregados, empregadores, gerentes, sindicatos e autoridades. O fenômeno estudado se situa a partir da década de noventa e trás conseqüências ao movimento trabalhista, ao emprego e às relações capital e trabalho pelo potencial de conflito que as privatizações apresentam. Para organizar o pensamento desenvolvemos uma abordagem histórica que mostra o desenvolvimento das relações trabalhistas, com as organizações aperfeiçoando os instrumentos de regulação de conflito e construindo, com os empregados, uma considerável experiência de convivência ainda que marcada por interesses imediatos conflitantes. Um pouco à frente observamos uma ruptura que é explicitada pela definição do modelo vigente, pela internacionalização da economia que é imposta como um determinismo histórico e pela necessidade de sobrevivência das empresas submetidas à globalização e competição sem fronteiras. Ainda procuramos entender o movimento de flexibilização dos direitos trabalhistas que de algum modo se constituem em obstáculo à equalização competitiva dos custos das empresas e estão a sofrer forte pressão para que possam se adequar às novas realidades econômicas e necessidades empresariais. Na narrativa dos fatos apontamos erros e acertos observados e, de forma crítica, sugerimos alternativas aos modelos políticos e gerenciais adotados.

Um processo de autogestão: crônica e crítica de uma experiência em psicologia institucional

O presente trabalho tem por objetivo fazer uma análise dos dados levantados pelo Departamento de Psicologia, de um Estabelecimento Escolar, que utiliza conceitos de Psicologia Institucional, desde a implantação (agosto de 1974), até o presente momento, (julho de 1978) pois seu desenvolvimento continua acontecendo. Durante este período os objetivos principais centralizaram-se em procurar investigar todas às formas do "latente" institucional a fim de desinvestir e desmontar as estruturas repressivas que pudessem estar impedindo o crescimento do estabelecimento no sentido de proporcionar um trabalho autogestivo com um máximo de liberdade e espírito crítico. Para que então, estes conceitos sejam aplicados tem-se praticado, de forma permanente, a metodologia da Análise Institucional, pois é através dela que se pretende realizar uma abordagem aos diferentes aspectos inconscientes e/ou desconhecidos da estrutura psico-socio-comunicacional do Estabelecimento. Tenta-se através de contextos técnicos vivenciais (grupos, etc) fazer com que os diferentes quadros do estabelecimento elaboremos aspectos acima mencionados, instrumentando-os para controlar as posições contraditórias, que ocupam, simultaneamente, todos os seus integrantes, por serem servidores do instituído e também encarregados de uma função instituinte.

Modulação quantizada para sistemas com codificação wavelet sujeitos ao desvanecimento rayleigh

Wavelet coding is an efficient technique to overcome the multipath fading effects, which are characterized by fluctuations in the intensity of the transmitted signals over wireless channels. Since the wavelet symbols are non-equiprobable, modulation schemes play a significant role in the overall performance of wavelet systems. Thus the development of an efficient design method is crucial to obtain modulation schemes suitable for wavelet systems, principally when these systems employ wavelet encoding matrixes of great dimensions. In this work, it is proposed a design methodology to obtain sub-optimum modulation schemes for wavelet systems over Rayleigh fading channels. In this context, novels signal constellations and quantization schemes are obtained via genetic algorithm and mathematical tools. Numerical results obtained from simulations show that the wavelet-coded systems derived here have very good performance characteristics over fading channels

Analysis of the different forms of application and types of cutting fluid used in plunge cylindrical grinding using conventional and superabrasive CBN grinding wheels

The work reported here involved an investigation into the grinding process, one of the last finishing processes carried out on a production line. Although several input parameters are involved in this process, attention today focuses strongly on the form and amount of cutting fluid employed, since these substances may be seriously pernicious to human health and to the environment, and involve high purchasing and maintenance costs when utilized and stored incorrectly. The type and amount of cutting fluid used directly affect some of the main output variables of the grinding process which are analyzed here, such as tangential cutting force, specific grinding energy, acoustic emission, diametrical wear, roughness, residual stress and scanning electron microscopy. To analyze the influence of these variables, an optimised fluid application methodology was developed (involving rounded 5, 4 and 3 turn diameter nozzles and high fluid application pressures) to reduce the amount of fluid used in the grinding process and improve its performance in comparison with the conventional fluid application method (of diffuser nozzles and lower fluid application pressure). To this end, two types of cutting fluid (a 5% synthetic emulsion and neat oil) and two abrasive tools (an aluminium oxide and a superabrasive CBN grinding wheel) were used. The results revealed that, in every situation, the optimised application of cutting fluid significantly improved the efficiency of the process, particularly the combined use of neat oil and CBN grinding wheel. (c) 2005 Elsevier Ltd. All rights reserved.

Analysis of surface integrity for minimum quantity lubricant - MQL in grinding

The quality of machined components is currently of high interest, for the market demands mechanical components of increasingly high performance, not only from the standpoint of functionality but also from that of safety. Components produced through operations involving the removal of material display surface irregularities resulting not only from the action of the tool itself, but also from other factors that contribute to their superficial texture. This texture can exert a decisive influence on the application and performance of the machined component. This article analyzes the behavior of the minimum quantity lubricant (MQL) technique and compares it with the conventional cooling method. To this end, an optimized fluid application method was devised using a specially designed nozzle, by the authors, through which a minimum amount of oil is sprayed in a compressed air flow, thus meeting environmental requirements. This paper, therefore, explores and discusses the concept of the MQL in the grinding process. The performance of the MQL technique in the grinding process was evaluated based on an analysis of the surface integrity (roughness, residual stress, microstructure and microhardness). The results presented here are expected to lead to technological and ecological gains in the grinding process using MQL. (c) 2006 Elsevier Ltd. All rights reserved.

Neural network detection of grinding burn from acoustic emission

An artificial neural network (ANN) approach is proposed for the detection of workpiece `burn', the undesirable change in metallurgical properties of the material produced by overly aggressive or otherwise inappropriate grinding. The grinding acoustic emission (AE) signals for 52100 bearing steel were collected and digested to extract feature vectors that appear to be suitable for ANN processing. Two feature vectors are represented: one concerning band power, kurtosis and skew; and the other autoregressive (AR) coefficients. The result (burn or no-burn) of the signals was identified on the basis of hardness and profile tests after grinding. The trained neural network works remarkably well for burn detection. Other signal-processing approaches are also discussed, and among them the constant false-alarm rate (CFAR) power law and the mean-value deviance (MVD) prove useful.

Evaluation of the performance of α-SiAlON tool when turning Ti-6Al-4V alloy without coolant

Due to their high hardness and wear resistance, Si3N4 based ceramics are one of the most suitable cutting tool materials for machining cast iron, nickel alloys and hardened steels. However, their high degree of brittleness usually leads to inconsistent results and sudden catastrophic failures. This necessitates a process optimization when machining superalloys with Si3N4 based ceramic cutting tools. The tools are expected to withstand the heat and pressure developed when machining at higher cutting conditions because of their high hardness and melting point. This paper evaluates the performance of α-SiAlON tool in turning Ti-6Al-4V alloy at high cutting conditions, up to 250 m min-1, without coolant. Tool wear, failure modes and temperature were monitored to access the performance of the cutting tool. Test results showed that the performance of α-SiAl0N tool, in terms of tool life, at the cutting conditions investigated is relatively poor due probably to rapid notching and excessive chipping of the cutting edge. These facts are associated with adhesion and diffusion wear rate that tends to weaken the bond strength of the cutting tool.

α-SiAION: Development and machining test on gray cast iron

The α-SiAlON ceramic cutting tool insert is developed. Silicon nitride and additives powders are pressed and sintered in the form of cutting tool inserts at temperature of 1900 °C. The physics and mechanical properties of the inserts like green density, weight loss, relative density, hardness and fracture toughness are evaluated. Machining studies are conducted on grey cast iron workpiece to evaluate the performance of α-SiAlON ceramic cutting tool. In the paper the cutting tool used in higher speed showed an improvement in the tribological interaction between the cutting tools and the grey cast iron workpiece resulted in a significant reduction of flank wear and roughness, because of better accommodation and the presence of the graphite in gray cast iron. The above results are discussed in terms of their affect at machining parameters on gray cast iron.

Turning of compacted graphite iron using commercial tiN coated Si 3N4 under dry machining conditions

Due to their high hardness and wear resistance Si3N4 based ceramics are one of the most suitable cutting tool materials for machining hardened materials. Therefore, their high degree of brittleness usually leads to inconsistent results and sudden catastrophic failures. Improvement of the functional properties these tools and reduction of the ecological threats may be accomplished by employing the technology of putting down hard coatings on tools in the state-of-the-art PVD processes, mostly by improvement of the tribological contact conditions in the cutting zone and by eliminating the cutting fluids. However in this paper was used a Si3N4 based cutting tool commercial with a layer TiN coating. In this investigation, the performance of TiN coating was assessed on turning used to machine an automotive grade compacted graphite iron. As part of the study were used to characterise the performance of cutting tool, flank wear, temperature and roughness. The results showed that the layer TiN coating failed to dry compacted graphite iron under aggressive machining conditions. However, using the measurement of flank wear technique, the average tool life of was increased by VC=160 m/min.The latter was also observed using a toolmakers microscope and scanning electron microscopy (SEM).

Cutting performance of diamond coated Si3N4 tool during turning

Silicon nitride cutting tools have been used successfully for machining hard materials, like: cast irons, nickel based alloys, etc. However these cutting tools with diamond coating present little information on dry turning operations of gray cast iron. In the present work, Si3N4 square inserts was developed, characterized and subsequently coated with diamond for dry machining operations on gray cast iron. All experiments were conducted with replica. It was used a 1500, 3000, 4500 m cutting length, feed rate of 0.33 mm/rev and keeping the depth of cut constant and equal to 1 mm. The results show that wear in the tool tips of the Si3N4 inserts, in all cutting conditions, was caused by both mechanical and chemical processes. To understand the tool wear mechanisms, a morphological analysis of the inserts, after experiments, has been performed by SEM and optical microscopy. Diamond coated PVD inserts showed to be capable to reach large cutting lengths when machining gray cast iron. © (2010) Trans Tech Publications.

Análise do processo de torneamento a quente auxiliado por resistência elétrica de quartzo

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