Operator's, manual : milling machine, ram type, swivel head, plain table, power feed, 1 1/2 horsepower, 110-volt, 60-cycle, single-phase (Van Norman Machine Company models IR-3-22 and IRQ-3-22) (3417-624-4254).

"March 1967."

Computer aided design and manufacture for three dimensional milling

Advances in both computer technology and the necessary mathematical models capable of capturing the geometry of arbitarily shaped objects has led to the development in this thesis of a surface generation package called 'IBSCURF' aimed at providing a more economically viable solution to free-form surface manufacture. A suit of computer programs written in FORTRAN 77 has been developed to provide computer aids for every aspect of work in designing and machining free-form surfaces. A vector-valued parametric method was used for shape description and a lofting technique employed for the construction of the surface. The development of the package 'IBSCURF' consists of two phases. The first deals with CAD. The design process commences in defining the cross-sections which are represented by uniform B-spline curves as approximations to give polygons. The order of the curve and the position and number of the polygon vertices can be used as parameters for the modification to achieve the required curves. When the definitions of the sectional curves is complete, the surface is interpolated over them by cubic cardinal splines. To use the CAD function of the package to design a mould for a plastic handle, a mathematical model was developed. To facilitate the integration of design and machining using the mathematical representation of the surface, the second phase of the package is concerned with CAM which enables the generation of tool offset positions for ball-nosed cutters and a general post-processor has been developed which automatically generates NC tape programs for any CNC milling machine. The two phases of these programs have been successfully implemented, as a CAD/CAM package for free-form surfaces on the VAX 11/750 super-minicomputer with graphics facilities for displaying drawings interactively on the terminal screen. The development of this package has been beneficial in all aspects of design and machining of free form surfaces.

Artificial neural networks for surface roughness prediction when face milling Al 7075-T7351

In this work, different artificial neural networks (ANN) are developed for the prediction of surface roughness (R a) values in Al alloy 7075-T7351 after face milling machining process. The radial base (RBNN), feed forward (FFNN), and generalized regression (GRNN) networks were selected, and the data used for training these networks were derived from experiments conducted using a high-speed milling machine. The Taguchi design of experiment was applied to reduce the time and cost of the experiments. From this study, the performance of each ANN used in this research was measured with the mean square error percentage and it was observed that FFNN achieved the best results. Also the Pearson correlation coefficient was calculated to analyze the correlation between the five inputs (cutting speed, feed per tooth, axial depth of cut, chip°s width, and chip°s thickness) selected for the network with the selected output (surface roughness). Results showed a strong correlation between the chip thickness and the surface roughness followed by the cutting speed. © ASM International.

Requalificação de uma máquina-ferramenta

Dissertação de mestrado integrado em Engenharia Mecânica

Optimising the design and manufacture of a customised, prescription fit, Maxillo-facial prosthesis

This thesis is a continuation of the Enterprise-Ireland Research Innovation Fund (RIF) Project entitled’ "Design and Manufacturing of Customised Maxillo-Facial Prostheses" The primary objective of this Internal Research Development Program (IRDP) project was to investigate two fundamental design changes 1 To incorporate the over-denture abutments directly into the implant. 2 To remove the restraining wings by the addition of screws, which affix the. implant to the dense material of the jawbone. The prosthetic was redesigned using the ANSYS Finite Element Analysis software program and analysed to* • Reduce the internal von Mises stress distribution The new prosthetic had a -63.63 % lower von Mises stress distribution when compared with the original prosthetic. • Examine the screw preload effects. A maximum relative displacement of 22 6 * lO^mm between the bone and screw was determined, which is well below the critical threshold of micromotion which prevents osseointegration • Investigate the prosthetic-bone contact interface. Three models of the screw, prosthesis, and bone, were studied. (Axisymmetnc, quarter volume, and full volume), a recommended preload torque of 0 32 Nm was applied to the prosthetic and a maximum von Mises stress of 1.988 MPa was predicted • Study the overdenture removal forces. This analysis could not be completed because the correct plastic multilinear properties of the denture material could not be established The redesigned prosthetic was successfully manufactured on a 3-axis milling machine with an indexing system The prosthetic was examined for dimensional quality and strength The research established the feasibility of the new design and associated manufacturing method.

Fliesslochformen und Gewindefurchen in dünne Bleche und Rohre aus Kupfer und Kupferlegierungen

This thesis in Thermal Flow Drilling and Flowtap in thin metal sheet and pipes of copper and copper alloys had as objectives to know the comportment of copper and copper alloys sheet metal during the Thermal Flow Drill processes with normal tools, to know the best Speed and Feed machine data for the best bushing quality, to known the best Speed for Form Tapping processes and to know the best bush long in pure copper pipes for water solar interchange equipment. Thermal Flow Drilling (TFD) and Form Tapping (FT) is one of the research lines of the Institute of Production and Logistics (IPL) at University of Kassel. At December 1995, a work meeting of IPL, Santa Catarina University, Brazil, Buenos Aires University, Argentine, Tarapacá University (UTA), Chile members and the CEO of Flowdrill B.V. was held in Brazil. The group decided that the Manufacturing Laboratory (ML) of UTA would work with pure copper and brass alloys sheet metal and pure copper pipes in order to develop a water interchange solar heater. The Flowdrill BV Company sent tools to Tarapacá University in 1996. In 1999 IPL and the ML carried out an ALECHILE research project promoted by the DAAD and CONICyT in copper sheet metal and copper pipes and sheet metal a-brass alloys. The normal tools are lobed, conical tungsten carbide tool. When rotated at high speed and pressed with high axial force into sheet metal or thin walled tube generated heat softens the metal and allows the drill to feed forward produce a hole and simultaneously form a bushing from the displacement material. In the market exist many features but in this thesis is used short and longs normal tools of TFD. For reach the objectives it was takes as references four qualities of the frayed end bushing, where the best one is the quality class I. It was used pure copper and a-brass alloys sheet metals, with different thickness. It was used different TFD drills diameter for four thread type, from M-5 to M10. Similar to the Aluminium sheet metals studies it was used the predrilling processes with HSS drills around 30% of the TFD diameter (1,5 – 3,0 mm D). In the next step is used only 2,0 mm thick metal sheet, and 9,2 mm TFD diameter for M-10 thread. For the case of pure commercial copper pipes is used for ¾” inch diameter and 12, 8 mm (3/8”) TFD drill for holes for 3/8” pipes and different normal HSS drills for predrilling processes. The chemical sheet metal characteristics were takes as reference for the material behaviour. The Chilean pure copper have 99,35% of Cu and 0,163% of Zinc and the Chilean a-brass alloys have 75,6% of Cu and 24,0% of Zinc. It is used two German a-brass alloys; Nº1 have 61,6% of Cu, 36,03 % of Zinc and 2,2% of Pb and the German a-brass alloys Nº2 have 63,1% of Cu, 36,7% of Zinc and 0% of Pb. The equipments used were a HAAS CNC milling machine centre, a Kistler dynamometer, PC Pentium II, Acquisition card, TESTPOINT and XAct software, 3D measurement machine, micro hardness, universal test machine, and metallographic microscope. During the test is obtained the feed force and momentum curves that shows the material behaviour with TFD processes. In general it is take three phases. It was possible obtain the best machining data for the different sheet of copper and a-brass alloys thick of Chilean materials and bush quality class I. In the case of a-brass alloys, the chemical components and the TFD processes temperature have big influence. The temperature reach to 400º Celsius during the TFD processes and the a-brass alloys have some percents of Zinc the bush quality is class I. But when the a-brass alloys have some percents of Lead who have 200º C melting point is not possible to obtain a bush, because the Lead gasify and the metallographic net broke. During the TFD processes the recrystallization structures occur around the Copper and a-brass alloy bush, who gives more hardness in these zones. When the threads were produce with Form Tapping processes with Flowtap tools, this hardness amount gives a high limit load of the thread when hey are tested in a special support that was developed for it. For eliminated the predrilling processes with normal HSS drills it was developed a compound tool. With this new tool it was possible obtain the best machining data for quality class I bush. For the copper pipes it is made bush without predrilling and the quality class IV was obtained. When it is was used predrilling processes, quality classes I bush were obtained. Then with different HSS drill diameter were obtained different long bush, where were soldering with four types soldering materials between pipes with 3/8” in a big one as ¾”. Those soldering unions were tested by traction test and all the 3/8” pipes broken, and the soldering zone doesn’t have any problem. Finally were developed different solar water interchange heaters and tested. As conclusions, the present Thesis shows that the Thermal Flow Drilling in thinner metal sheets of cooper and cooper alloys needs a predrilling process for frayed end quality class I bushings, similar to thinner sheets of aluminium bushes. The compound tool developed could obtain quality class I bushings and excludes predrilling processes. The bush recrystalization, product of the friction between the tool and the material, the hardness grows and it is advantageous for the Form Tapping. The methodology developed for commercial copper pipes permits to built water solar interchange heaters.

Aplicação de redes neurais artificiais na predição de diâmetro e rugosidade durante o processo de furação

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Desenvolvimento de uma nova sistemática para centragem e alinhamento da plataforma giratória R-9350 na mandriladora CNC PAMA SPEEDRAM 3000

In heavy machining industries, a critical point that must be taken into account is setup. Because the characteristics of machine tools and parts to be machined, usually pieces robust and large, the preparation of these parts must be made accurately for machining has a good result as planned. As a result of the difficulty raised in the setup machining of heavy parts, companies in this segment seek alternatives to reduce the unproductive time caused by setup and optimize machining processes. One way was found that these companies create operating instructions that describe and standardize the operation between its employees, as well as deploy a control machining times to measure the unproductive time caused by the setup. This work studied a new system for the realization of centering and alignment of Rotating Deck R-9350 in CNC Milling Machine PAMA Speedram 3000, in Liebherr Brazil company. The part Rotating Deck R-9350 is a critical part in which its machining in PAMA Milling Machine is made in three phases and their setup times are quite high and involve stopping the machine. It has been tested and proposed a solution to the realization of this part of the setup without the use of the machine, but of the measuring instrument three-dimensional Laser tracker, with which the machine continued to work, while he was in the centering and alignment of other parts. It was noted that the instrument technically attended the need and it was possible to perform this operation more accurately

A utilização das tecnologias assistidas por computador como elemento de integração, pesquisa e desenvolvimento nas disciplinas de projeto para a engenharia e design

The use of technologies called computedassisted, such as CAD - (Computed Aided Design), CAM - (Computed Aided Manufacturing) and CNC - (Computed Numerical Control), increasingly demanded by the market, are needed in the teaching of subjects technical drawing and design courses for engineering and design. However its use findl barriers in the more conservative wing of the academy, who advocate the use of traditional drawing, for the settling of the concepts and the development of spatial reasoning. This study aimed to show the results obtained with the design and production of an apparatus for measuring a three-dimensional computer-aided milling machine, interaction, integration and consolidation of concepts, fully demonstrating that the learning of computer-assisted technology is possible, and its use is most appropriate, meaningful and productive, than the use of instruments in the classic design.

Análise e aferição de uma fresadora CNC através da utilização das tecnologias assistidas por computador, no escaneamento 3D de amostras e processamento de imagens

The use of computer-assisted technologies such as CAD - Computed Aided Design, CAM - Computed Aided Manufacturing, CAE - Computed Aided Engineering and CNC - Computed Numerical Control, are priorities in engineering and product designers. However, the dimensional measurement between the virtual and the real product design requires research, and dissemination procedures among its users. This work aims to use these technologies, through analysis and measurement of a CNC milling machine, designed and assembled in the university. Through the use of 3D scanning, and analyzing images of the machined samples, and its original virtual files, it was possible to compare the sizes of these samples in counterposition to the original virtual dimensions, we can state that the distortions between the real and virtual, are within acceptable limits for this type of equipment. As a secondary objective, this work seeks to disseminate and make more accessible the use of these technologies.

Estudio Energético y de Explotación de diferentes conjuntos de Labranza para el Cultivo de la Yuca (Manihot esculenta, Crantz) en un Fluvisol

El trabajo se desarrolló en tres etapas de investigación, las dos primeras fueron realizadas en la Unidad Básica de Producción Cooperativa “El Palmar” perteneciente a la Empresa de Cultivos Varios "Paquito Rosales Benítez" del municipio de Yara, provincia de Granma, Cuba, el cual se llevó a cabo en el período de abril de 2005 a enero de 2008; y de noviembre de 2012 a febrero de 2013 respectivamente; la tercera se ejecutó de mayo a junio de 2013 en un canal de suelo ubicado en la nave de maquinaria del Departamento de Ingeniería Rural de la Universidad Politécnica de Madrid. En la primera etapa se evaluaron los conjuntos tractor-apero que intervienen en la realización de cuatro sistemas de labranza para el cultivo de la yuca, variedad Enana Rosada. Los sistemas de laboreo fueron: T1, labor de aradura (alzado) con un arado de discos seguidas de un pase de grada de discos un pase cruzado de un escarificador y un pase con una grada de discos (5 labores); T2, laboreo mínimo que comprende una labor profunda con un escarificador con saetas seguido por una labor de grada de discos (2 labores); T3, laboreo mínimo en el que se realizaron dos pases cruzados con escarificador y una labor de fresado con una fresadora de eje horizontal (3 labores) y; T4, dos labores cruzadas con la grada de discos seguidas por otras dos pases cruzados con el escarificador y una última labor con la grada de discos (5 labores). Se realizaron cinco observaciones de la jornada laboral para cada uno de los conjuntos tractorapero de cada sistema de laboreo en tres campañas, evaluando el consumo de combustible, las diferentes productividades, los índices y coeficientes tecnológicos y de explotación, el rendimiento del cultivo el balance energético del mismo, y la emisión de CO2 equivalente. En la segunda etapa se determinó la fuerza de tiro requerida por un órgano de trabajo de un escarificador con saetas en condiciones de campo, en tres profundidades (15, 25 y 35 cm) y a cuatro velocidades de trabajo (1,30; 1,49; 1,65 y 2,32 m s-1). En la tercera etapa se determinaron las fuerzas horizontales y verticales en una maqueta experimental de un órgano de trabajo de un escarificador con saetas (1:5 del tamaño real del apero) en cuatro contenidos de humedad (60, 90, 120 y 150 g kg-1), tres densidades del suelo (1,1; 1,2 y 1,3 Mg m-3) y una velocidad de 40 mm s-1. Se comparan los resultados del apero a tamaño real y la maqueta experimental. Los mejores resultados relacionados con los indicadores evaluados a la maquinaria correspondieron al sistema de laboreo mínimo T2, el cual presenta la mejor productividad por hora de tiempo limpio (1,34 ha h-1) y de tiempo operativo (1,27 ha h-1), con diferencias significativas respecto al resto de los sistemas de labranza evaluados; así como el menor consumo de combustible (32,4 L ha-1) y el mejor comportamiento energético, con diferencias significativas respecto a las demás, resultando inferior en un 63, 30 y 58 % con relación a T1, T3 y T4. La fuerza de tiro del órgano de trabajo del escarificador con saetas se incrementa con la densidad del suelo y con la profundidad, y velocidad de trabajo. Las fuerzas horizontales y verticales de la maqueta se incrementan linealmente con la densidad y humedad del suelo. Existe una relación lineal entre las fuerzas de tiro y horizontales medidas en el apero real y en el apero a escala con el contenido de humedad del suelo. ABSTRACT The work was developed in three stages of research, the first two were conducted in the Basic Unit of Cooperative Production "El Palmar" belonging to the agricultural farm "Paquito Rosales Benitez" in the municipality of Yara, Granma Province, Cuba, the which was conducted in the period from April 2005 to January 2008 and November 2012 and February 2013 respectively, the third from May to June 2013 on a soilbin located in the ship's machinery of Rural Engineering Department of the Technical University of Madrid. In the first stage were evaluated tractor-implement sets involved in the completion of four tillage systems for cassava, Pink Dwarf variety. Tillage systems were: T1, plowing (elevation) with a disk plow followed by a pass of disc harrow, a cross of scarifier and a pass with a disc harrow (5 labours), T2, minimum tillage comprising a deep work with a scarifier with a bolt followed by a disc harrow work (two labours); T3, minimum tillage which two crossed passes performed with scarifier and milling labour with a horizontal axis milling machine (three labours) and, T4, two crossed labours with disc harrow followed by two crossed passes with the scarifier and a final labour with disc harrow (5 labours). Five observations of the working day for each tractor-implement sets of each tillage system in three seasons were performed, evaluating fuel consumption, different productivities, indexes and technological and operational factors, the crop yield energy balance and the emission of CO2 equivalent. In the second stage we determined the draft force required by a working body of a scarifier with bolt under field conditions at three depths (15, 25 and 35 cm) and four operating speeds (1.30, 1.49 , 1.65 and 2.32 m s-1). In the third stage were determined horizontal and vertical forces on an experimental model of a working body of a scarifier with bolt (1:5 real scale of the implement) in four moisture contents (60, 90, 120 and 150 g kg -1), three soil densities (1.1, 1.2, and 1.3 Mg m-3) and a speed of 40 mm s-1.The results of real scale implement the experimental model were compared. The best results related to evaluated machinery indicators corresponded to T2 minimum tillage system, which presents the best productivity per hour clean time (1.34 ha h-1) and operating time (1.27 ha h-1), with significant differences compared to other tillage systems evaluated; as well as lower fuel consumption (32.4 L ha-1) and the best energy performance, with significant differences from the other, resulting lower by 63, 30 and 58% compared to T1, T3 and T4. The draft force of the working body of the scarifier with bolt increases with soil density and depth, and speed of work. The horizontal and vertical forces of the model increase linearly with density and soil moisture. A linear relationship exists between the shot and horizontal forces measured at the real implement and scale implement with the soil moisture content.

Avaliação do processamento por atrito linear em chapas da liga de titânio Ti-6Al-4V.

Esta tese tem por objetivo a aplicação do processamento por atrito linear na liga de titânio Ti-6Al-4V. Derivado da solda por atrito linear, é um processo recente desenvolvido na década de 90 para união de alumínio. Sua aplicação em outros tipos de materiais como aços e ligas de alto desempenho, em especial o titânio, tem interessado a industria. A metodologia utilizada nesta tese para avaliar o processamento por atrito linear, consistiu na execução de ensaios mecânicos de tração em condições mistas em chapas da liga de titânio Ti-6Al-4V. A máquina utilizada para o processamento das chapas foi um centro de usinagem CNC convencional, adaptado com dispositivos especiais. Além dos ensaios de tração em condições mistas, foram executadas medições de microdurezas nas regiões atingidas pelo processo, avaliação das microestruturas resultantes e medições de tensão residual para uma caracterização mais ampla do processo. As microestruturas na região processada são caracterizadas por uma estrutura totalmente transformada. As temperaturas de pico na região processada excederam a temperatura -transus durante o processamento e a transformação da fase + ocorreu durante a fase de resfriamento. A transformação da fase para resultou na formação de agulhas de fase nos contornos e pelo interior dos grãos da fase . Pequenas regiões com estrutura equiaxial de grãos ( globular) foram observados na zona de processamento. A abordagem dos resultados quantitativos foi feita de forma estatística, visando identificar os parâmetros de maior interação com os resultados observados. Foi identificado nesta tese que a rotação da ferramenta apresentou a maior influência nos resultados de tensão residual, microdureza e tensão de escoamento. Uma importante contribuição à modelagem da tensão de escoamento para materiais anisotrópicos é proposta, baseado em um critério de escoamento ortotrópico. Equações complementares baseadas nos testes mistos de tração e cisalhamento são propostas para modificar o modelo ortotrópico. O intuito deste modelo é indicar em que condições o material tem seu regime de escoamento atingido, podendo servir de base para simulações práticas de peças em condições similares.

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.