<p>The cylinder liners’ surface is really important in an engine because it corresponds with piston rings to a tribologic system indispensable to know for reasons of wear, of oil consumption and engine’s life time. For these reasons, it is important to measure and characterize these surfaces.</p><p>The first part of the project is the observation of the impact of the number of strokes of the plateau honing on the surface of the cylinder liners. It is interesting to observe the impact of the variation of the number of strokes of the plateau honing on the peaks, plateaus and valleys of the surface.</p><p>The second part of the project is the simulation of the oil flow on the surface to observe the links between the roughness parameters and the oil flow and the shear stress.</p><p>The results are interesting, we will observe that the number of strokes of honing as a good impact on the quality of the surface.</p><p>In the second part of the project, the results show a correlation between the machining parameters and the roughness and functional parameters.</p><p>It could be interesting to mix the two parts of the project to see the correlation among machining, roughness and functional parameters for the samples made in the first of the project.</p>

The cylinder liners’ surface is really important in an engine because it corresponds with piston rings to a tribologic system indispensable to know for reasons of wear, of oil consumption and engine’s life time. For these reasons, it is important to measure and characterize these surfaces. The first part of the project is the observation of the impact of the number of strokes of the plateau honing on the surface of the cylinder liners. It is interesting to observe the impact of the variation of the number of strokes of the plateau honing on the peaks, plateaus and valleys of the surface. The second part of the project is the simulation of the oil flow on the surface to observe the links between the roughness parameters and the oil flow and the shear stress. The results are interesting, we will observe that the number of strokes of honing as a good impact on the quality of the surface. In the second part of the project, the results show a correlation between the machining parameters and the roughness and functional parameters. It could be interesting to mix the two parts of the project to see the correlation among machining, roughness and functional parameters for the samples made in the first of the project.

Orientador: Amauri Hassui / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-12T23:13:39Z (GMT). No. of bitstreams: 1 RossiNeto_Eneas_M.pdf: 13972971 bytes, checksum: 1c7b89f4fdc28248118cde9b4b90db25 (MD5) Previous issue date: 2009 / Resumo: Neste trabalho procurou-se estudar e desenvolver um processo inédito de usinagem para ser implementado na manufatura dos cilindros automotivos, componentes muito importantes utilizados nos motores de automóveis que possuem bloco de alumínio. São poucos e conhecidos os fabricantes do segmento automotivo que fabricam este produto, sendo que, até então, todos utilizavam operação de mandrilamento para usinagem do diâmetro interno da camisa. Entre outras vantagens, este trabalho propõe aumentar a produtividade de maneira significativa, atendendo todas as especificações técnicas do produto. A operação de mandrilamento foi substituída por torneamento interno, utilizando um centro de torneamento com sistema de carga e descarga integrado, ferramentas de corte e dispositivos de fixação especiais e estratégias de usinagem diferenciadas. As camisas para cilindro são fabricadas de ferro fundido cinzento centrifugado, um material extremamente abrasivo que requer cuidados na sua manufatura. Após o desenvolvimento completo do processo e prévios ensaios de usinagem para definição das premissas, utilizou-se uma metodologia objetiva para otimização do processo proposto, realizada no ambiente fabril, considerando todas as variáveis encontradas nas condições reais de produção. Os resultados obtidos mostraram que os insertos de metal duro com cobertura apresentaram um melhor desempenho que os insertos de cerâmica à base de nitreto de silício e de óxido de alumínio na aplicação em estudo, sendo constatado também as melhores condições de corte para o torneamento interno de cilindros automotivos de ferro fundido cinzento centrifugado / Abstract: This investigation describes and shows an unprecedented machining process to be used for manufacturing cylinder liners, which are very important parts used in aluminum engine blocks for automobiles. There are few known companies that manufacture this kind of component, and until now, all of them use a boring process to machine the internal diameter of the cylinder liner. Among other advantages, this investigation intends to increase significantly productivity, while respecting all technical specifications of the product. The boring process was replaced by internal turning, which uses a turning center with load/unload system, special cutting tools and clamp devices, as well as audacious machining strategies. The cylinder liners are made from centrifuged gray cast iron, an extreme abrasive material that needs special care during its machining process. After the complete development of the process and tryouts to define the preliminary data, it has been used an objective methodology to optimize the proposed process, developed on the shop floor, considering all the variables found in real production conditions. The investigation results shown the carbide inserts had better performance than the silicon nitride and aluminum oxide ceramic inserts in this studied application, evidencing the best cutting conditions to internal turning for cylinder liners made of centrifuged gray cast iron / Mestrado / Materiais e Processos de Fabricação / Mestre em Engenharia Mecânica

Made available in DSpace on 2016-03-15T19:37:00Z (GMT). No. of bitstreams: 1 Dionisio Mateo Cardille.pdf: 3138784 bytes, checksum: c27dcdc2765d16f7b30f2b6a5a588e37 (MD5) Previous issue date: 2009-08-18 / This study broaches the diesel engines cylinder liners waste concepts, characterizing abrasive waste, tribo-chemical waste and scuffing, with component external factors, like adultered fuel or with high sulfur level frequently found in Brazil. It presents the modern emissioned engines and the direct causes in the cylinder liners material requirement, with the tribologic evolution of piston, piston rings and cylinder. Some concepts of cylinders internal diameter surface finish and the direct involvement in the cylinder smooth, and the blow by flux besides oil consumption. The cylinder liners are manufactured in perlitic gray casting iron, and it was compared to a bainitic gray casting iron as alternative material, in order to satisfy the modern environment laws for emissions. The experiment technical was based on a dynamometric test in a 146kw diesel engine, during 500hs, with 27,4% overpower. The liners were assembled in the engine block in an intercalated way, avoiding benefits in the cylinders closer to the water pump. After the test, the liners were dimensioned with the respective piston rings. As result, was observed that the proposal bainitic material got a better waste resistance in comparison with the perlitic material, with a better dimensional stability. The piston rings presented similar waste when applied in both materials, respecting the project original tribological pair. / Este estudo aborda os conceitos de desgaste em camisas de cilindro para motores diesel, caracterizando desgaste abrasivo, tribo-químico e "scuffing", juntamente com fatores externos ao componente como a questão dos combustíveis adulterados ou com alto teor de enxofre, freqüentemente encontrados no Brasil. Apresenta o enquadramento dos motores nas modernas leis de emissões, e suas causas diretas na exigência de materiais para camisas de cilindro, juntamente com a evolução tribológica do conjunto pistão, anéis e camisa. Definem-se também alguns conceitos de rugosidade e acabamento superficial dos cilindros e suas implicações diretas no amaciamento neste componente, além do tema passagem de gases da câmara de combustão para o cárter (blow by) e consumo de óleo lubrificante. As camisas de cilindro são em sua maioria confeccionadas em liga de ferro fundido cinzento com matriz perlítica, a qual foi objeto de comparação com uma liga proposta de matriz bainítica, como material alternativo, visando satisfazer as condições impostas pela moderna legislação ambiental. A técnica experimental empregada baseou-se em um ensaio dinamométrico em um motor diesel de 146kw, porém submetido a plena carga durante 500hs, com 27,4% de acréscimo de potência. As camisas foram montadas no motor de forma a estarem intercaladas e evitando favorecimentos em cilindros mais quentes do bloco. Após o teste, as camisas de cilindro foram dimensionadas, juntamente com os respectivos anéis de pistão. Como resultado, observou-se que o material proposto em liga com matriz bainítica teve uma melhor resposta ao desgaste em comparação com o material de matriz perlítica, inclusive com uma melhor estabilidade dimensional. Os anéis de pistão tiveram desgaste similar em ambos os materiais, respeitando o par tribológico original de projeto.