Diploma work describes speed drill steels and its qualities before and after coating by methods PVD (Physical Vapour Deposition). The theoretic part is concerned with thermic processing of speed drill steels and their qualities with regard to individual alloying elements contained and its mechanical features. Second part of the theoretic part is concerned with particular methods of coating by the help of PVD technologies, kinds of coating with regard to additional elements and their qualities and surface treatments of coated material before and after its coating. The goal of the experimental part was the confrontation of cutting power features of cylindrical four-fluted face mills with straight shank, from speed drill steels non-coated and coated in two basic modes of milling – down-feed method and upfeed method. The results of measurements were interpreted by the help of four basic pictures (source values, power analysis, specific values). The result of all the experiment is that the application of PVD coatings enabled the increasing of cutting speed (with preservation of other cutting requirements) and led to decreasing of cutting force and cutting enforcements and extended durability of cutters.

In the first part of this diploma thesis there are discribed basic findings about cutting ceramics (sorts, notation, structure, physical-mechanical properties, using, production) and it evaluates this tool material from the aspect of cutting power. The second part focuses on complex data processing about assortment of ceramics cutting materials of significant tool materials producers and comparison of service conditions (kind of mechanided materials, cutting conditions), which are recommend for effective turning by producers.

Les travaux présentés dans cette thèse s'inscrivent un contexte d'amélioration de la productivité des pièces en TA6V. La maîtrise de l'usinage de cet alliage constitue un enjeu majeur pour les sous-traitants comme l'entreprise SOFOP qui doivent suivre les montées en cadence des principaux programmes aéronautiques. La première partie, basée sur un état de l'art académique, s'attache à identifier différents critères d'usinabilité du matériau au travers de plusieurs échelles. Dans un second temps, la démarche du Couple Outil-Matière (COM) est mise en œuvre sur deux outils utilisés par l'industriel afin de déterminer un espace de fonctionnement des conditions opératoires garantissant une amélioration de la productivité. La confrontation entre les résultats de la campagne expérimentale du COM et de l'application en contexte industriel a permis de souligner le fort impact de la stratégie d'usinage sur la durée de vie de l'outil de coupe. L'influence sur les mécanismes d'usure de la vitesse de coupe, souvent utilisée comme paramètre d'ajustement de la durée de vie en production, ainsi que de l'engagement radial de l'outil inhérent au parcours a été investiguée au travers d'un dispositif expérimental spécialement équipé d'une caméra thermique. Les liens entre les champs de températures et l'usure de l'outil de coupe ont ensuite été établis par des analyses MEB et EDX. L'étude phénoménologique ne permettant pas de pondérer l'impact des parcours d'usinage sur la durée de vie de l'outil de coupe, une approche statistique a alors été adoptée. Basée sur la récolte de la puissance de coupe en usinage, les corrélations établies entre les caractéristiques des signaux et la durée de vie de l'outil ont abouti à la proposition d'une modélisation expérimentale, fiabilisée vers de deux applications industrielles : une méthode de prédiction en amont de la production et une approche de surveillance de l'étatd'usure de l'outil en usinage / The work presented in this thesis aims at improving productivity when manufacturing TA6V parts. Knowledge and control of the milling process for this titanium alloy are a key challenge particularly for medium size companies like SOFOP who try to answer the increasing aeronautical parts market demand. The first section is focused on machinability criteria which are discussed through several scales. Then, following the couple tool-material method, working zones of two tools are determined in order to achieve productivity improvements. This results, obtained through laboratory tests have been faced with their industrial application and showed the strong links between milling paths and tool life. Influence of cutting speed and radial engagement has been investigated with a specifically developed experimental bench, equipped with a thermal camera. Indeed, the rst parameter is often considered as an adjustment variable for tool life during the validation phase and the other one is deeply linked with tool path. Temperature fields and tool wear have been correlated thanks to SEM and EDX images. Given the fact that the phenomenological study is not able to weight the impact of the tool path on tool life, a statistical approach hase been adopted. Based on cutting power signal collection, correlations have been established between signal features and tool life and led to the proposal of a verified experimental model allowing to consider two industrial applications : a tool life prediction method during the industrialization phase and an online tool life monitoring approach

Considerando as dimensões reduzidas das ferramentas de microfresamento, a seleção não otimizada dos parâmetros de corte tende a maximizar o desgaste e a quebra da ferramenta durante operações de microusinagem. Isto posto, o desenvolvimento de um sistema de monitoramento para explorar as condições da microfresa durante a usinagem é fundamental. Portanto, o objetivo desta pesquisa é monitorar via sinais de potência e emissão acústica (EA) o desgaste da ferramenta e a estabilidade de corte em operações de microfresamento do aço COS AR60 e COS AR60 de grãos ultrafinos (GUF). Os testes de microfresamento foram realizados com ferramentas de diâmetro de 1 mm e duas arestas, com substrato de metal duro e revestimento (Ti, Al, Cr) N, em um centro de usinagem CNC Romi D800 High Performance adaptado com um cabeçote de alta rotação. O microfresamento ocorreu nos dois materiais sem aplicação de fluido de corte e com velocidade de corte de 62,5 m/min e 125 m/min, mantendo constante a velocidade de avanço de 240 mm/min (fz = 6 μm/aresta e 3 μm/aresta), profundidade de usinagem de 100 m e comprimento de usinagem de 104 mm em corte em cheio. O sinal de potência e EA foram adquiridos à taxa de 5 kHz e 1,25 MHz, respectivamente. Os dados foram adquiridos em LabVIEW® e processados em LabVIEW® e MATLAB®. Os resultados de caracterização dos desgastes apontaram um desgaste de flanco mais expressivo e a formação de Aresta Postiça de Corte (APC) no GUF para vc = 125 m/min, e a presença de desgaste de cratera em todas as condições de corte. O aumento da potência de corte média representou a predominância do desgaste de flanco, e desgaste de cratera em sua redução. De forma semelhante, a ANOVA dos valores de EA RMS indicaram com significância (95% de confiança) uma correlação diretamente proporcional entre EA RMS e evolução do desgaste de flanco na microfresa. Quanto à estabilidade de corte, ambos os sinais apresentaram um aumento expressivo de amplitude quando o corte foi instável. Com isso, os métodos de monitoramento utilizados foram capazes de indicar a evolução do desgaste da microfresa e a ocorrência de chatter em operações de microfresamento. / Regarding the reduced dimensions of micro-milling tools, a non-optimised selection of cutting parameters tends to maximise tool wear and breakage during cutting operations. Hereupon the development of a monitoring system for exploring microtool conditions during machining is imperative. Therefore, the aim of this research is to monitor tool wear and cutting stability via cutting power and acoustic emission (AE) signals in micro-milling operations of steel COS AR60 and ultra fine-grained steel COS AR 60 (GUF). Cutting tests were performed by carbide endmill tools with (Ti, Al, Cr) N coating, two flutes and 1 mm diameter in a CNC machining centre Romi D800 High Performance adapted with a high spindle speed head. Micro-milling operations were carried out in both materials without cutting fluid application at 62.5 m/min and 125 m/min, and constant parameters of feed, set at 240 mm/min (fz = 6 μm/tooth and 3 μm/tooth), depth of cut of 100 m and cutting length of 104 mm performed in sloth cutting strategy. Cutting power and AE signals were acquired at the rate of 5 kHz and 1.25 MHz, respectively. The data were acquired in LabVIEW® and processed in both LabVIEW® and MATLAB®. The results on wear characterisation revealed a major flank wear and the formation of Built Up-Edge (BUE) in GUF at vc = 125 m/min, along with the occurrence of crater wear in all cutting conditions set. An increase in the average cutting power levels is linked to the predominancy of flank wear, while crater wear to its decrease. Likewise, the Analysis of Variance (ANOVA) of EA RMS values indicated with significancy (95% confidence) a direct proportion between AE RMS and flank wear in the microtool. In terms of cutting stability both EA and cutting power signals have shown an expressive rise when performing instable cutting. Thus, the methods of monitoring were feasible for recognising tool wear evolution and chatter in micro-milling operations.

The assessment of MQL technology application in reaming process was elaborated in this diploma work. The evaluation of energy intensity was carried out in terms of specific cutting force during reaming of austenitic stainless steel work piece by using HSS reamers. The comparison of economic costs in the case of the application of MQL technology in production was made. Confrontation of oil mist removal principles. At the conclusion the evaluation of ecological benefits for the environment and the positive influence on the working environment cleanness was defined.

n the first part of this diploma thesis there are described basic findings about superhard cutting materials (sorts, notation, structure, physical-mechanical properties, usage, production) and evaluates this tool of material from the aspect of cutting ability. The second part focused on complex data processing about assortment of superhard cutting materials of significant tools materials producers and comparison of work conditions (kind of machined ma-terials, cutting conditions), which are recommend for effective turning applica-tions by producers.

In the first part of this thesis is discussed of the possibilities of surface grinding. There are described various methods for grinding and describe their characteristics. Furthermore, there is shown the marking of grinding wheels and is discussed of their composition and of calculating the cutting forces. In the second part of this thesis the experiment is performed. On the samples of various materials are monitored parameters of roughness after grinding, which is used by conventional grinding BPH 300 and horizontal lathe from company TDZ Turn.

Orientador: Manoel Cleber de Sampaio Alves / Resumo: A superliga de níquel VAT 32® foi desenvolvida como um substituto da liga UNS N07751 (Inconel 151) na fabricação de válvulas automotivas para motores de combustão interna de alto desempenho. A formação de carbonetos de nióbio confere a esta liga elevada resistência ao desgaste, desejada na aplicação em válvulas automotivas, criando-se, porém, uma maior dificuldade na usinagem deste material. Este trabalho estudou o torneamento da liga VAT 32® com quatro tipos de ferramentas de corte. São elas insertos de metal duro com diferentes revestimentos, Ti(C,N) + Al2O3 pelo processo de deposição química de vapor (chemical vapor deposition – CVD), e revestimento de Ti-Al-Si-N pelo processo de deposição física de vapor (physical vapor deposition – PVD), pastilhas de nitreto cúbico de boro (cBN) e pastilhas experimentais de Al2O3 + MgO. Através do método de Taguchi de planejamento experimental, foram obtidas as combinações e os efeitos principais dos parâmetros velocidade de corte, avanço da ferramenta, profundidade de usinagem e tipo de lubrificação (seco ou em abundância) para otimizar cada uma das variáveis respostas, sendo elas potência de usinagem, desgaste das ferramentas, qualidade superficial das peças usinadas, e os sinais de emissão acústica e vibração do processo. Foram obtidos também, através da análise da razão sinal-ruído (S/N) de Taguchi, a composição dos parâmetros de corte em que o processo apresentou menor variabilidade das características de qualidade, o chamado proces... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: VAT 32® is a nickel based super alloy developed to substitute UNS N07751 alloy in production of automotive valves for high performance internal combustion engines. The formation of niobium carbides gives to this alloy a high resistance to wear, desired in the application in automotive valves, creating however, a greater difficulty in the machining of this material. This thesis aimed the study of VAT 32® turning with four different cutting tools. The tested tools were Ti(C,N)+Al2O3 coated by chemical vapor deposition (CVD) carbide inserts, Ti-Al-Si-N coated by physical vapor deposition (PVD) carbide inserts, cubic boron nitrite (cBN) inserts and experimental Al2O3+MgO ceramic inserts. Optimal combination of the cutting parameters and main effects of the factors speed of cutting, tool feed, depth of cutting and lubrication condition (dry and abundant) in turning of VAT 32® were found using Taguchi’s method as a design of experiment (DOE). The analyzed response variables were machining power, tool wear, surface quality of the machined pieces, chips format and acoustic emission and vibration signals of the process. It was also obtained in this work the robust process with the analysis of signal to noise ratio (S/N) where cutting parameters for smaller process variability were found. Finally, the multi-objective optimization method called Grey Relational Analysis (GRA) was used to find optimal cutting conditions for each tested tools. These optimal conditions were used in a tool l... (Complete abstract click electronic access below) / Doutor

Este trabalho tem como objetivo avaliar o desempenho metrológico de 15 unidades eletrocirúrgicas de dois fabricantes e três modelos diferentes quando submetidos a variações de temperatura ambiente. Para tanto foram considerados cinco níveis do fator temperatura e três pontos da faixa nominal das potências de corte e de coagulação. Os ensaios foram realizados acoplando a unidade eletrocirúrgica objeto de avaliação a um analisador de potência. O teste de Tukey foi aplicado visando efetuar múltiplas comparações entre os níveis do fator temperatura. Os parâmetros metrológicos incerteza de medição, erro, repetibilidade e erro máximo foram estimados para todos as unidades avaliadas. A incerteza associada à medição foi avaliada de acordo com as recomendações do Guia para a Expressão da Incerteza de Medição (GUM). A análise de variância (ANOVA), o teste de Tukey e o boxplot indicaram efeitos estatisticamente significativos do fator temperatura nos valores de potência de corte e coagulação avaliados. A incerteza expandida associada aos valores de potência de corte e de coagulação aumentou de forma significativa na medida em que estas se aproximaram do limite superior da faixa nominal. Foram observadas diferenças significativas entre as unidades eletrocirúrgicas dos fabricantes A e B sobre tudo para menores valores de potência. Neste sentido as unidades do fabricante A apresentaram desempenho superior. Nas potências de corte 50 W, 150 W e 300 W, observou-se que 33 %, 87 % e 100 %, respectivamente, das unidades avaliadas apresentaram valores de erro máximo maiores que 5 W e portanto não atendem ao critério especificado pelo fabricante. Para as potências de coagulação, 30 W, 80 W e 120 W estas porcentagens foram respectivamente de 0, 53 % e 60 %. As unidades eletrocirúrgicas avaliadas apresentam um desempenho que podem comprometer o sucesso do processo cirúrgico. / The objective of this work is to evaluate the metrological performance of 15 electrosurgical unit from two manufacturers and three different models when subjected to ambient temperature variations. For this, five levels of the temperature factor and three points of the nominal range of the cutting and coagulation powers were considered. The tests were performed by coupling the evaluation electrosurgical unit to a power analyzer. The Tukey test was applied in order to make multiple comparisons between the levels of the temperature factor. The metrological parameters measurement uncertainty, error, repeatability and maximum error were estimated for all evaluated electrosurgical unit. The uncertainty associated with the measurement was evaluated according to the recommendations of the Guide to the Expression of Uncertainty in Measurement (GUM). Analysis of variance (ANOVA), Tukey test and boxplot indicated significant statistically effects of the temperature factor on the cutting and coagulation power values. The expanded uncertainty associated with cutting and coagulation power values increased significantly as they approached the upper limit of the nominal range. Significant differences were observed between the scalpels of manufacturers A and B mainly for lower power values. The scalpels of the manufacturer A presented superior performance. At 50 W, 150 W and 300 W cutting powers, it was observed that 33 %, 87 % and 100 %, respectively, of the scalpels had maximum error values greater than 5 W and therefore they did not meet the criterion specified by the manufacturer (maximum error must be less than 5 W). For the coagulation powers, 30 W, 80 W and 120 W these percentages were respectively 0, 53 % and 60 %. The electrosurgical unit evaluated have a metrological performance that can compromise the success of the surgical process. / Dissertação (Mestrado)

Fundação de Amparo a Pesquisa do Estado de Minas Gerais / The main objective of the present work is to study the effect of the input variables: mechanical properties of the workpiece (tensile strength, hardness and elongation) and cutting conditions (cutting speed, feed rate, depth of cut and lubri-cooling system) over the output variables: cutting forces, power consumption, cutting temperature, surface roughness (Ra, Rz and Rq parameters) and toolholder vibration in turning of aluminum alloys: 1350-O, 6082-T4, 6262-T6,7075-T73 e 7075-T6. This set of alloys covers a large range of properties of the aluminum alloys. A 2k factorial planning and a Central Composite Design (CCD) were used to determine the machining test conditions. After ANOVA and Regression analysis of the results, 2nd order models were generated, relating the input and the output variables for each aluminum alloy and also globally (considering the properties of the alloys). Surface Response Method SRM, level curves and gradient vector generated after the models were used to present and analyze the influence of the input variables and their interactions on the output parameters. Validated models used in a multi-response optimization process (genetic algorithm) identified the levels of the input variables that simultaneously optimize all the output parameters. The most important contribution of this work on the machining of aluminum alloys lies on its efficiency of describing the behavior of each machining characteristic (output variable) as a function of the input variable interactions within the range studied. Many researches on machining of aluminum alloys describe, in an isolated form, the behavior of the machining characteristics (output parameters) as functions of a few or only one factor, limiting the conclusions about the machinability of these alloys. In the present work it was observed that generally the machining output parameters varied individually according to the literature, however, new behavior, due to the interaction of the input variables, so far not described by previous work was presented. / Este trabalho objetiva estudar o efeito das variáveis de entrada: propriedades mecânicas da peça (resistência mecânica, dureza e alongamento) e condições de corte (velocidade de corte, avanço, profundidade de corte e sistema de lubri-refrigeração) sobre as variáveis de saída (respostas): forças de usinagem; potência de usinagem; temperatura de corte; parâmetros de rugosidade: Ra, Rz e Rq e vibração do suporte da ferramenta no torneamento das ligas de alumínio: 1350-O, 6082-T4, 6262-T6, 7075-T73 e 7075-T6. Estas ligas cobrem uma larga faixa de propriedades das ligas de alumínio. Para este estudo foi utilizado o planejamento fatorial 2k completo e o planejamento composto central (PCC), para determinar as condições de ensaios de usinagem. A partir de análise de variância e de regressão dos resultados foram gerados modelos de 2ª ordem, relacionando, em cada liga de alumínio, e também de forma global (considerando as propriedades das ligas), as respostas com as entradas. Superfícies de respostas, curvas de níveis e vetor gradiente gerados a partir desses modelos foram utilizados para apresentar e analisar as influências das entradas, por interação entre fatores, sobre as respostas. Modelos validados foram utilizados em um processo de otimização multiresposta (algoritmo genético), que identificou os níveis das entradas que otimizassem, simultaneamente, todas as respostas. A grande contribuição deste trabalho, relacionado com a usinabilidade das ligas de alumínio, repousa em sua capacidade de descrever o comportamento da característica de usinabilidade (resposta) em função das interações das entradas em sua região de variação. Muitas pesquisas envolvendo a usinagem das ligas de alumínio descrevem de forma isolada o comportamento das características de usinabilidade em função de alguns fatores ou apenas um único fator, o que limita grandemente as conclusões sobre a variação das características de usinabilidade. Neste trabalho se observou, de maneira geral, que as características de usinabilidade variaram de forma isolada com os fatores, de acordo com o registrado na literatura, mas novos comportamentos das características de usinabilidade, ainda não descritos na literatura, devido à interação entre fatores foram presenciados. / Doutor em Engenharia Mecânica