published_or_final_version / Industrial Engineering / Doctoral / Doctor of Philosophy

Thesis (Ph. D.)--Rutgers University, 2007. / "Graduate Program in Industrial and Systems Engineering." Includes bibliographical references (p. 226-236).

O objetivo do trabalho foi fabricar ferramentas de corte para usinagem a partir de materiais em gradação funcional (Functionally Graded Materials FGM), fazendo uso da técnica de sinterização por plasma pulsado (Spark Plasma Sintering SPS), a qual permite taxa de aquecimento e resfriamento maior do que as técnicas tradicionais, menor temperatura e tempo de operação, melhor controle energético e alta repetibilidade. Os materiais utilizados foram pós cerâmicos a base de alumina (Al2O3-ZrO2 e Al2O3-TiC) e metal duro (WC-Co), de modo que dois insertos foram desenvolvidos, um de cerâmica branca (Al2O3-ZrO2) em gradação com metal duro e outro de cerâmica mista (Al2O3-TiC) em gradação com metal duro. A metodologia experimental levou em conta a aplicação de um modelo termomecânico para estimar a tensão residual térmica ao longo da espessura da ferramenta, estudo da influência dos parâmetros de sinterização por SPS (Temperatura e Pressão) sobre a qualidade do sinterizado (caracterização da propriedade física, densidade), com base nesses dados foi escolhida a melhor condição de operação para fabricar corpos de prova (CPs) para os ensaios mecânicos de resistência à flexão, dureza e tenacidade à fratura, além de insertos em FGM para os ensaios de usinagem em ferro fundido cinzento fazendo uso da operação de torneamento. Os resultados mostraram que o parâmetro de máquina que mais influenciou a densidade foi a Temperatura, os FGMs de AlTiC e AlZr obtiveram um aumento de 126 e 73% na resistência à flexão em relação às suas respectivas cerâmicas homogêneas, seguindo a sequência dos materiais, a dureza foi avaliada em 13,8 e 15,8 GPa, enquanto a tenacidade à fratura em 4,91 e 5,04 MPa.m1/2. Quanto aos ensaios de usinagem, as ferramentas de FGM AlZr apresentaram menor desgaste do que as de FGM AlTiC, as forças de corte foram influenciadas pelas variáveis Avanço e Velocidade de corte, finalmente, o Avanço foi a variável que mais influenciou os resultados de rugosidade. / The aim was fabricating cutting tools from functionally graded materials (FGM) by spark plasma sintering method (SPS), which allow heating and cooling rates higher than traditional methods, lower temperature and shorter time sintering, better energy control and high reproducibility. The materials used were ceramic powders based on alumina (Al2O3-ZrO2 and Al2O3-TiC) and cemented carbide (WC-Co), so that two inserts were developed, one of white ceramic (Al2O3-ZrO2) graded with cemented carbide and the other of mixed ceramic (Al2O3- TiC) graded with cemented carbide. The experimental methodology was developed from thermo-mechanical model application to estimate thermal residual stress along with tool thickness, study into the influence of SPS sintering parameters (Temperature and Pressure) over sintered quality (physical properties characterization, density), on the basis of these data, the best operating condition was chosen to fabricate workpieces for mechanical tests of flexural strength, hardness and fracture toughness, besides FGM inserts to machining tests in grey cast iron using turning operation. The results showed the machine parameter that mostly influenced density was Temperature; the AlTiC and AlZr FGMs got an increase of 126 and 73% in flexural strength in relation to their homogeneous ceramics. Following the materials sequence, the hardness was evaluated at 13.8 and 15.8 GPa, whereas the fracture toughness was 4.91 and 5.04 MPa.m1/2. For the machining tests, FGM AlZr cutting tools showed lower wear than FGM AlTiC ones; the cutting forces were influenced by Feed Rate and Cutting Speed. Finally, the Feed Rate was the variable that mostly influenced the roughness results.

Orientador: Amauri Hassui / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-23T09:41:04Z (GMT). No. of bitstreams: 1 Machado_MarcioAlexandreGoncalves_M.pdf: 7046476 bytes, checksum: c4116e182c526a80c0f1d8c7b1fe8d4a (MD5) Previous issue date: 2013 / Resumo: Sabe-se que atualmente a competitividade das empresas é fator de sobrevivência. Assim, a busca por redução de custo é um constante desafio. Um aspecto dentro dos processos de fabricação que atua diretamente nesse tocante é o desenvolvimento de melhores ferramentas de corte. Este trabalho trata da reafiação de ferramentas de corte denominadas bedame, que possuem custo mais elevado que as demais ferramentas. O material usinado foi o ferro fundido nodular, que possui propriedades mecânicas características e consumir menor energia em sua fusão. Nos processos de usinagem são utilizadas as mesmas ferramentas para os ferros fundidos nodulares e cinzentos, porém o primeiro é um material dúctil, diferente do segundo que é frágil. Isso implica em um comportamento diferente na usinagem, mostrando que cabe neste caso uma melhor adequação das ferramentas de corte. Após a utilização de bedames novos, estes foram reafiados em quatro modelos diferentes. Posteriormente foram testados quatro tipos de revestimento PVD. Na sequência avaliou-se também a influência da velocidade de corte, avanço e concentração do fluido de corte. O critério adotado para a determinação do fim da vida dos bedames foi à qualidade da face usinada. Os ensaios foram feitos em sequência, sendo que o passo seguinte utilizava apenas os melhores resultados do passo anterior. Os resultados indicaram que bedames com ângulo de saída positivo, revestidos com AlTiN, usinando com menores velocidades de corte e avanço e com maior concentração de óleo no fluido de corte, apresentaram vida mais longa. Por outro lado, o mesmo bedame, só que revestido com TiCN e operando nas mesmas condições, apresentou a melhor relação custo benefício dentre os bedames reafiados. Concluiu-se assim que é viável economicamente a reafiação dos bedames / Abstract: It is known nowadays that the companies' competitiveness is a survival factor. So, the search for cost reduction is a constant challenge. One aspect of the manufacturing processes that act directly in this aspect is the development of better cutting tools. This work is about cutting tools to part materials named parting tools that has higher costs than the other cutting tools. The machined material was the nodular cast iron that has specific mechanical characteristics and demands less energy in its melting. In the machining processes it is usually used the same cutting tools to machine nodular and grey cast iron, but the first is ductile different from the second that is fragile. This implies in a different machining behavior, showing that is possible in this case a better adequation of the cutting tools. After using the new parting tools, they were resharpened in four different models. After that were tried four different PVD coatings. In the sequence it was also evaluated the influence of the cutting speed, the feed and cutting fluid concentration. The criteria adopted to determine the end of the parting tool life was the quality of the machined surface. The tests were carried out in sequence in such a way that the next step used just the best results of the former step. The results indicated that parting tool with positive rake angle, coated with AlTiN, operating in lower cutting speeds and feeds and with higher cutting fluid concentration, presented longer tool life. On the other hand, the same parting tool, but coated with TiCN and operating at the same cutting conditions, presented a better cost benefit relation among the resharpened cutting tools. It can be concluded that is economically feasible the parting tools resharpening / Mestrado / Materiais e Processos de Fabricação / Mestre em Engenharia Mecânica

The Physical Vapour Deposition (PVD) magnetron sputtering process is one of the widely used techniques for depositing thin film coatings on substrates for various applications such as integrated circuit fabrication, decorative coatings, and hard coatings for tooling. In the area of coatings on cutting tools, tool life can be improved drastically with the application of hard coatings. Application of coatings on cutting tools for various machining techniques, such as continuous and interrupted cutting, requires different coating characteristics, these being highly dependent on the process parameters under which they were formed. To efficiently optimise and customise the deposited coating characteristics, PVD process modelling using RSM methodology was proposed. The aim of this research is to develop a PVD magnetron sputtering process model which can predict the relationship between the process input parameters and resultant coating characteristics and performance. Response Surface Methodology (RSM) was used, this being one of the most practical and cost effective techniques to develop a process model. Even though RSM has been used for the optimisation of the sputtering process, published RSM modelling work on the application of hard coating process on cutting tool is lacking. This research investigated the deposition of TiAlN coatings onto tungsten carbide cutting tool inserts using PVD magnetron sputtering process. The input parameters evaluated were substrate temperature, substrate bias voltage, and sputtering power; the out put responses being coating hardness, coating roughness, and flank wear (coating performance). In addition to that, coating microstructures were investigated to explain the behaviour of the developed model. Coating microstructural phenomena assessed were; crystallite grain size, XRD peak intensity ratio I111/I200 and atomic number percentage ratio of Al/Ti. Design Expert 7.0.3 software was used for the RSM analysis. Three process models (hardness, roughness, performance) were successfully developed and validated. The modelling validation runs were within the 90% prediction interval of the developed models and their residual errors compared to the predicted values were less than 10%. The models were also qualitatively validated by justifying the behaviour of the output responses (hardness, roughness, and flank wear) and microstructures (Al/Ti ratio, crystallographic peak ratio I111/1200, and grain size) with respect to the variation of the input variables based on the published work by researchers and practitioners in this field. The significant parameters that influenced the coating hardness, roughness, and performance (flank wear) were also identified. Coating hardness was influenced by the substrate bias voltage, sputtering power, and substrate temperature; coating roughness was influenced by sputtering power and substrate bias; and coating performance was influenced by substrate bias. The analysis also discovered that there was a significant interaction between the substrate temperature and the sputtering power which significantly influenced coating hardness, roughness, and performance; this interaction phenomenon has not been reported in previously published literature. The correlation study between coating characteristics, microstructures and the coating performance (flank wear) suggested that the coating performance correlated most significantly to the coating hardness with Pearson coefficient of determination value (R2) of 0.7311. The study also suggested some correlation between coating performance with atomic percentage ratio of Al/Ti and grain size with R2 value of 0.4762 and 0.4109 respectively.

A thesis submitted to the Faculty of Science, University of the Witwatersrand, in fulfilment of the requirements for the degree of Doctor of Philosophy. Johannesburg, 2015. / The progress achieved on research of the different handaxe-bearing regions of China is making the study of the Acheulean an exciting and important field in the Chinese Palaeolithic. However, compared with other well-known Large Cutting Tool or LCT-bearing regions, e.g., Bose in southern China and Luonan in central China, the work in the Danjiangkou Reservoir Region (DRR) is still at the stage of data collection, and deeper research into the meaning of these materials is still under way. In international academic circles, the DRR is almost never considered in the latest discussions about the Chinese Acheulean. The work in this thesis attempts to improve this situation. The thesis is presented as four published papers and one submitted paper of Acheulean materials from the DRR, central China. Through a detailed study of these materials from typological, technological and morphological perspectives, I have now achieved significant understanding of the Acheulean techno-complex in DRR, especially in its regional variability and adaptation compared with other Acheulean regions in China. Lastly, the questions that are still awaiting resolution in the future are also discussed.

A dissertation submitted to the Faculty of Science, University of the Witwatersrand, in fulfilment of the requirements for the degree of Masters of Science in Archaeology. Johannesburg, 2015 / Large cutting tools (LCTs) are a stone tool techno-group that appeared ca. 1.76 Ma in Africa and marked the beginning of the Acheulean. The group is conventionally comprised of three tool types called handaxes, cleavers, and picks. The function of LCTs has only been determined through assumptions (e.g., names based on historical antecedents or assigning functional names to morpho-types) or through experimental tasks designed to determine if a particular tool type was efficient for a given task, (e.g., are handaxes conducive to butchery tasks?). To date, no extensive use-wear analysis has been carried out on African Acheulean LCTs. This is the pioneering study. Utilising a multi-stranded approach comprised of experimental archaeology, blind testing and low- power use-wear analysis the functions of a sample of LCTs from The Cave of Hearths were derived. The Cave of Hearths (CoH) lies in the Makapan Valley in the Limpopo Province of South Africa. Excavations were carried out from 1947 to 1954, and it is these excavations from which this study draws its sample. Thirty-eight handaxes and cleavers from the CoH Bed 3 Acheulean (ca. 0.5 Ma) were submitted to a low-power use-wear analysis. The results showed that a full range of tasks was performed on site including: wood- working, animal and vegetal matter processing, accompanied by digging and a number of other tasks. Corroborated by faunal analysis and an environmental reconstruction, the results suggest that the cave acted as a home camp/ residential base to the hominins that inhabited the area during the Acheulean. Additionally, evidence was found which may indicate that two of the tools were possibly hafted. If this finding is corroborated by future studies it would push back by approximately 150 Ka the earliest date previously published for hafting with Mode 3 tools.

No presente trabalho foram desenvolvidos compósitos à base de alumina, com adição de carbetos de metais de transição, NbC, TaC e TiC, como reforço. Os carbetos, na forma de partículas, foram adicionados em 1,5% em volume à matriz de alumina durante a moagem em attritor. O processamento foi realizado por moagem em attritor, secagem em rotoevaporadora e desaglomeração em peneira. A dinâmica de oxidação dos carbetos e das composições dos compósitos foi estudada para a definição de parâmetros de sinterização e processamento dos compósitos. A cinética de sinterização foi estudada por dilatometria, com taxa de 10°C/min. até 1600°C em atmosfera de ar sintético, e até 1800°C, em atmosfera de argônio, com esta etapa foi possível verificar que o NbC e o TiC dificultaram a sinterização da alumina e que o TaC auxiliou nos processos de retração. Nas amostras que foram sinterizadas em dilatômetro ao ar foram detectadas fases resultantes de fusão congruente nos compósitos Al2O3/NbC e Al2O3/TaC, foram também observadas evidências de formação de líquido no compósito com adição de TaC. Com base nesses resultados foram estudadas duas técnicas de produção das ferramentas de corte: prensagem uniaxial seguida de sinterização sem pressão e sinterização por prensagem a quente. Todas as amostras foram caracterizadas microestruturalmente e quanto às propriedades mecânicas, tendo-se determinado que as amostras produzidas por prensagem a quente possuem microestrutura mais controlada e propriedades mecânicas superiores às produzidas por sinterização sem pressão. Pelos processos estudados foi observado que os carbetos influenciam diferentemente a sinterização da alumina. De maneira geral a presença destas fases nos contornos de grãos promove alterações na microestrutura modificando o tamanho de grãos da alumina. Foi proposta a hipótese de que esse comportamento é afetado pela formação de uma camada superficial resultante da oxidação dos reforços, com isto, de acordo com os diagramas de fase é possível a formação de soluções sólidas entre alumina e Ta2O5 e Nb2O5 além da formação de fase líquida, estes mecanismos alterariam a mobilidade dos contornos de grão da alumina. Para o processamento das ferramentas de corte foi utilizada prensagem a quente, escolhido pelo critério da microestrutura e propriedades mecânicas. Os testes de usinagem foram realizados com ferramentas de corte de geometria quadrada, em peças de ferro fundido cinzento e vermicular. O tempo de vida útil da ferramenta produzida com o compósito Al2O3/ NbC foi 13% superior quando comparado à uma ferramenta cerâmica comercial no teste de usinagem de ferro fundido cinzento. / In the present work alumina based composites with addition of transition metal carbides, NbC, TaC and TiC as reinforcement phase were developed. The carbides, in particulate form, were added in 1.5vol.% on the alumina matrix during attritor milling. The processing was conducted by attritor milling, drying in a rotoevaporator and deagglomeration in sieve. The oxidation dynamics of carbides and composities were studied in order to define the sintering and processing parameter of composites. The sintering kinetics was studied by dilatometry at 10° C/min. up to 1600 ° C in synthetic air atmosphere and up to 1800°C in argon, with this step it was possible to verify that the NbC and TiC hindered the sintering of alumina and the TaC helped in the retraction process. In the sintered by dilatometer in air phases resultant from congruent melting on Al2O3/NbC and Al2O3/TaC composites were detected in the composite with TaC addition was also observed evidence of liquid phase. In the samples sintered in dilatometer in air were detected solid solutions on composites CN and CTa and evidence of liquid formation in the composite with TaC addition. Based on these results two techniques were studied in order to produce cutting tools: uniaxial pressing, followed by pressureless sintering and hot pressing. All samples were characterized by microstructure and mechanical properties, and it was shown that samples produced by hot pressing have more controlled microstructure and mechanical properties superior to those produced by pressureless sintering. With the studied processes it was observed that the carbides influence differently alumina sintering. Generally the presence of these phases at the grain boundary causes changes in the microstructure modifying alumina grain size alumina. The proposed hypothesis is that this behavior would be affected by the formation of a surface layer resulting from oxidation of reinforcements with that, according to the phase diagrams, it is possible to find solid solutions between alumina and Ta2O5 and Nb2O5 and possible formation of liquid phase, which alter the mobility of the grain boundary of alumina. Hot pressing was used for the processing of cutting tools, chosen due to the microstructure and mechanical properties. The machining tests were performed with square geometry cutting tools, in samples of gray cast iron and compacted graphite iron. The tool life of cutting tool produced with Al2O3 / NbC composite was 13% higher when compared to a commercial ceramic cutting tool on machining of gray cast iron.

No presente trabalho foram desenvolvidos compósitos à base de alumina, com adição de carbetos de metais de transição, NbC, TaC e TiC, como reforço. Os carbetos, na forma de partículas, foram adicionados em 1,5% em volume à matriz de alumina durante a moagem em attritor. O processamento foi realizado por moagem em attritor, secagem em rotoevaporadora e desaglomeração em peneira. A dinâmica de oxidação dos carbetos e das composições dos compósitos foi estudada para a definição de parâmetros de sinterização e processamento dos compósitos. A cinética de sinterização foi estudada por dilatometria, com taxa de 10°C/min. até 1600°C em atmosfera de ar sintético, e até 1800°C, em atmosfera de argônio, com esta etapa foi possível verificar que o NbC e o TiC dificultaram a sinterização da alumina e que o TaC auxiliou nos processos de retração. Nas amostras que foram sinterizadas em dilatômetro ao ar foram detectadas fases resultantes de fusão congruente nos compósitos Al2O3/NbC e Al2O3/TaC, foram também observadas evidências de formação de líquido no compósito com adição de TaC. Com base nesses resultados foram estudadas duas técnicas de produção das ferramentas de corte: prensagem uniaxial seguida de sinterização sem pressão e sinterização por prensagem a quente. Todas as amostras foram caracterizadas microestruturalmente e quanto às propriedades mecânicas, tendo-se determinado que as amostras produzidas por prensagem a quente possuem microestrutura mais controlada e propriedades mecânicas superiores às produzidas por sinterização sem pressão. Pelos processos estudados foi observado que os carbetos influenciam diferentemente a sinterização da alumina. De maneira geral a presença destas fases nos contornos de grãos promove alterações na microestrutura modificando o tamanho de grãos da alumina. Foi proposta a hipótese de que esse comportamento é afetado pela formação de uma camada superficial resultante da oxidação dos reforços, com isto, de acordo com os diagramas de fase é possível a formação de soluções sólidas entre alumina e Ta2O5 e Nb2O5 além da formação de fase líquida, estes mecanismos alterariam a mobilidade dos contornos de grão da alumina. Para o processamento das ferramentas de corte foi utilizada prensagem a quente, escolhido pelo critério da microestrutura e propriedades mecânicas. Os testes de usinagem foram realizados com ferramentas de corte de geometria quadrada, em peças de ferro fundido cinzento e vermicular. O tempo de vida útil da ferramenta produzida com o compósito Al2O3/ NbC foi 13% superior quando comparado à uma ferramenta cerâmica comercial no teste de usinagem de ferro fundido cinzento. / In the present work alumina based composites with addition of transition metal carbides, NbC, TaC and TiC as reinforcement phase were developed. The carbides, in particulate form, were added in 1.5vol.% on the alumina matrix during attritor milling. The processing was conducted by attritor milling, drying in a rotoevaporator and deagglomeration in sieve. The oxidation dynamics of carbides and composities were studied in order to define the sintering and processing parameter of composites. The sintering kinetics was studied by dilatometry at 10° C/min. up to 1600 ° C in synthetic air atmosphere and up to 1800°C in argon, with this step it was possible to verify that the NbC and TiC hindered the sintering of alumina and the TaC helped in the retraction process. In the sintered by dilatometer in air phases resultant from congruent melting on Al2O3/NbC and Al2O3/TaC composites were detected in the composite with TaC addition was also observed evidence of liquid phase. In the samples sintered in dilatometer in air were detected solid solutions on composites CN and CTa and evidence of liquid formation in the composite with TaC addition. Based on these results two techniques were studied in order to produce cutting tools: uniaxial pressing, followed by pressureless sintering and hot pressing. All samples were characterized by microstructure and mechanical properties, and it was shown that samples produced by hot pressing have more controlled microstructure and mechanical properties superior to those produced by pressureless sintering. With the studied processes it was observed that the carbides influence differently alumina sintering. Generally the presence of these phases at the grain boundary causes changes in the microstructure modifying alumina grain size alumina. The proposed hypothesis is that this behavior would be affected by the formation of a surface layer resulting from oxidation of reinforcements with that, according to the phase diagrams, it is possible to find solid solutions between alumina and Ta2O5 and Nb2O5 and possible formation of liquid phase, which alter the mobility of the grain boundary of alumina. Hot pressing was used for the processing of cutting tools, chosen due to the microstructure and mechanical properties. The machining tests were performed with square geometry cutting tools, in samples of gray cast iron and compacted graphite iron. The tool life of cutting tool produced with Al2O3 / NbC composite was 13% higher when compared to a commercial ceramic cutting tool on machining of gray cast iron.

Thesis (M.S.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering, 1981. / MICROFICHE COPY AVAILABLE IN ARCHIVES AND ENGINEERING. / Includes bibliographical references. / by Paul Dudley Hartung. / M.S.